Repair of aircraft components by laser cladding process

Liu, Qianchu; Sharp, P. K.; Brandt, Milan; Matthews, Neil; Sun, Stephen Teng; Djugum, Richard

doi:10.2351/1.5063074

Cited by 4 publications

(3 citation statements)

References 1 publication

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“…By switching the input-material feedstock, layers of material with different compositions can be deposited on the build area. This approach is often used for repairs to give enhanced corrosion and wear properties to the component [57,58]. Moreover, compared to PBF systems, the heat conduction in DED processes is more effective because the heat, material, and shield gas are transferred directly from the nozzle to the build area, whereas the powder bed in PBF systems acts as a heat insulator [12].…”

Section: Directed Energy Depositionmentioning

confidence: 99%

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Review: The Impact of Metal Additive Manufacturing on the Aerospace Industry

Yusuf

Cutler

Gao

2019

Metals

215

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Metal additive manufacturing (AM) has matured from its infancy in the research stage to the fabrication of a wide range of commercial functional applications. In particular, at present, metal AM is now popular in the aerospace industry to build and repair various components for commercial and military aircraft, as well as outer space vehicles. Firstly, this review describes the categories of AM technologies that are commonly used to fabricate metallic parts. Then, the evolution of metal AM used in the aerospace industry from just prototyping to the manufacturing of propulsion systems and structural components is also highlighted. In addition, current outstanding issues that prevent metal AM from entering mass production in the aerospace industry are discussed, including the development of standards and qualifications, sustainability, and supply chain development.

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Section: Directed Energy Depositionmentioning

confidence: 99%

“…Lower accuracy than PBF AM processes. [58]. Although newly purchased anti-rotation brackets are relatively cheap, long lead times of up to 18 months drew the attention of the RAAF to additive repairs and specifically to those by DED.…”

mentioning

confidence: 99%

Review: The Impact of Metal Additive Manufacturing on the Aerospace Industry

Yusuf

Cutler

Gao

2019

Metals

215

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“…Large, high-value structural components, such as those used in marine [1], power generation [2][3][4], aerospace [5,6], and heavy machinery [7] applications, are often difficult to source and expensive to replace after in-service damage. Furthermore, in many instances the damage is either localised (i.e.…”

Section: Introductionmentioning

confidence: 99%

Direct comparison of Cold Metal Transfer to laser hot-wire cladding for AISI 4340 structural steel repair

Munro

Chen

2020

Science and Technology of Welding and Joining

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Repair, rather than replacement, of large, high-value structural components can reduce overall operating costs, with wire-based cladding techniques preferable due to their relatively high deposition rates. Two such techniques, laser hot-wire cladding and Cold Metal Transfer, are particularly attractive for their low heat input, which reduces distortion, filler metal dilution and thermal effects on the substrate. However, literature studies on the use of these techniques for structural steel repair are limited, with no studies offering a direct comparison of their performance. In the present work, laser hot-wire cladding is directly compared to Cold Metal Transfer for the repair of AISI 4340 structural steel. Simulated repairs using the same base/filler metal and joint geometry are characterised in terms of distortion, microstructure, tensile and impact properties. The results show that, despite having similar laser and arc energies, the two techniques resulted in significantly different properties, generally due to differences in process efficiencies.

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Feasibility of laser cladding for tooling repair in aerospace manufacturing: an alternative to chrome plating

Koruba,

Pawlicki,

Mróz

et al. 2024

Arch. Civ. Mech. Eng.

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Advanced remanufacturing by additive manufacturing is challenging in aerospace due to the minimization of material costs, preparation times and metal waste. This study analyzed a 40HM low-alloy steel ring as a demo tooling used to produce aircraft engine components. The possibility of using laser cladding with powder process with the additive material NiCrBSi alloy powder was analyzed. Optimal parameters of the process were selected in terms of the assumed structural requirements (geometrical parameters of the clad, its hardness and the size of the heat-affected zone) for the remanufactured surfaces, ultimately obtaining a crack-free multilayer coating with a thickness of 2 mm and a hardness of above 700 HV1. The remanufacturing process was performed on three representative surfaces: flat face, cylindrical external, and internal. This approach allowed an analysis of the possibilities of finishing the laser-deposited layers with the machining methods used in the actual tooling department of the aerospace company: turning, milling, grinding, and center grinding. During chip processing, the defects (holes, cracks) made machining difficult and ineffective, mainly due to accelerated tool wear. Single cracks were observed after the grinding operation, which may reduce the durability of the remanufacturing layer. Both the changes in the microstructure of the demo component and the phases present in the cladding were analyzed. The deposition process was found to form a martensitic structure in the substrate at the cross-section in proximity to the remanufactured surfaces. This was also confirmed by an increase in average hardness from 402 HV1 to 605 HV1 for the analyzed substrate areas.

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Repair of aircraft components by laser cladding process

Cited by 4 publications

References 1 publication

Review: The Impact of Metal Additive Manufacturing on the Aerospace Industry

Review: The Impact of Metal Additive Manufacturing on the Aerospace Industry

Direct comparison of Cold Metal Transfer to laser hot-wire cladding for AISI 4340 structural steel repair

Feasibility of laser cladding for tooling repair in aerospace manufacturing: an alternative to chrome plating

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