Adaptive toolpath deposition method for laser net shape manufacturing and repair of turbine compressor airfoils

Qi, Huan; Azer, Magdi; Singh, Prabhjot

doi:10.1007/s00170-009-2265-7

Cited by 107 publications

(38 citation statements)

References 13 publications

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“…Lack-of-fusion pores can be eliminated by optimizing the laser heat input and geometric toolpath parameters, i.e., bead overlap ratio and bead aspect ratio. [11] In this study, experiments were designed in order to minimize the porosity caused by hollow powders and entrapped gas bubbles. Three types of IN718 powders with different particle size distributions and manufacturing methods were investigated (as shown in Table II).…”

Section: A Process Optimizationmentioning

confidence: 99%

Studies of Standard Heat Treatment Effects on Microstructure and Mechanical Properties of Laser Net Shape Manufactured INCONEL 718

Azer

Ritter

2009

Metall Mater Trans A

479

209

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Laser net shape manufacturing (LNSM) is a laser cladding/deposition based technology, which can fabricate and repair near-net-shape high-performance components directly from metal powders. Characterizing mechanical properties of the laser net shape manufactured components is prerequisite to the applications of LNSM in aircraft engine industrial productions. Nickelbased superalloys such as INCONEL 718 are the most commonly used metal materials in aircraft engine high-performance components. In this study, the laser deposition process is optimized through a set of designed experiments to reduce the porosity to less than 0.03 pct. It is found that the use of plasma rotating electrode processed (PREP) powder and a high energy input level greater than 80 J/mm are necessary conditions to minimize the porosity. Material microstructure and tensile properties of laser-deposited INCONEL 718 are studied and compared under heat treatment conditions of as deposited, direct aged, solution treatment and aging (STA), and full homogenization followed by STA. Tensile test results showed that the direct age heat treatment produces the highest tensile strength equivalent to the wrought material, which is followed by the STA-treated and the homogenization-treated tensile strengths, while the ductility exhibits the reverse trend. Finally, failure modes of the tensile specimens were analyzed with fractography.

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Section: A Process Optimizationmentioning

confidence: 99%

Studies of Standard Heat Treatment Effects on Microstructure and Mechanical Properties of Laser Net Shape Manufactured INCONEL 718

Azer

Ritter

2009

Metall Mater Trans A

479

209

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“…by CAx systems. Online adaptions are already in use today [8] and can be applied with less effort than offline adaptions, since their underlying dependencies are limited to input generated during process execution. In contrast, offline adaptions are often applied manually [27] or by very specialized software with restricted repair cases [11].…”

Section: Adaptive Manufacturing Process Chainsmentioning

confidence: 99%

“…A typical horizontal process chain in the processing of formed sheet parts contains cutting, forming and joining [7]. Another example is the repair manufacturing process chain of worn turbine blades through additive laser cladding and re-contouring [8,2,9].…”

Section: Flexibility In Manufacturing Process Chainsmentioning

confidence: 99%

Programming of adaptive repair process chains using repair features and function blocks

Spöcker

Schreiner

Huwer

et al. 2015

Journal of Computational Design and Engineering

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The current trends of product customization and repair of high value parts with individual defects demand automation and a high degree of flexibility of the involved manufacturing process chains. To determine the corresponding requirements this paper gives an overview of manufacturing process chains by distinguishing between horizontal and vertical process chains. The established way of modeling and programming processes with CAx systems and existing approaches is shown. Furthermore, the different types of possible adaptions of a manufacturing process chain are shown and considered as a cascaded control loop. Following this it is discussed which key requirements of repair process chains are unresolved by existing approaches. To overcome the deficits this paper introduces repair features which comprise the idea of geometric features and defines analytical auxiliary geometries based on the measurement input data. This meets challenges normally caused by working directly on reconstructed geometries in the form of triangulated surfaces which are prone to artifacts. Embedded into function blocks, this allows the use of traditional approaches for manufacturing process chains to be applied to adaptive repair process chains

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“…Another motivation for flexibility is the need to repair used parts because of their high-value and to increase resource efficiency [28]. Repairing wornout parts can require highly adapted repair process chains based on the part's current geometry [3,20]. Until now the required process chains are often programmed manually by experienced personnel or by highly specialized software tools and are therefore only applicable to one variant at a time [3,38,39].…”

Section: Introductionmentioning

confidence: 99%

Reducing data loss within adaptive process chains in the context of commonly-used CAx systems

Klocke

Spöcker

Huwer

et al. 2015

Prod. Eng. Res. Devel.

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In many industries the focus in CAx based manufacturing has changed from fixed process chains to ones which can adapt to dynamic inputs. This way process chains can take measurement data into account to produce optimal results. Unfortunately, existing approaches do not integrate well with the existing CAx systems since they do not ensure that existing processes will be kept unchanged. This restriction leads to a low adaption rate in some industries. Especially in the aerospace industry every change in the manufacturing processes will result in high costs. In this paper it is shown that an extended function block approach can be integrated with existing CAx systems while allowing the modeling and controlling of adaptive process chains with reduced data loss at the same time. In order to achieve this goal, data port manifests are introduced which announce supported data formats and features of the corresponding function block. This extension reduces information loss at system interfaces and helps to ensure that required data will be transferred between function blocks. A case study will show how this extension can be used in a common CAx system

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Adaptive toolpath deposition method for laser net shape manufacturing and repair of turbine compressor airfoils

Cited by 107 publications

References 13 publications

Studies of Standard Heat Treatment Effects on Microstructure and Mechanical Properties of Laser Net Shape Manufactured INCONEL 718

Studies of Standard Heat Treatment Effects on Microstructure and Mechanical Properties of Laser Net Shape Manufactured INCONEL 718

Programming of adaptive repair process chains using repair features and function blocks

Reducing data loss within adaptive process chains in the context of commonly-used CAx systems

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