TY - CONF A1 - Merz, Benjamin A1 - Poka, Konstantin A1 - Mohr, Gunther A1 - Hilgenberg, Kai T1 - Precise Position Detection for Repair of Gas Turbine Blades using PBF-LB/M N2 - Additive manufacturing (AM) technologies are becoming increasingly important, not only for the manufacture of parts, but also as repair technology that complement existing production technologies. Powder bed fusion of metals by laser beam (PBF-LB/M) combines the freedom in design with high achievable accuracy, making it ideal as a repair approach. However, there are still challenges in adapting process for repair applications. When mounting parts inside PBF-LB/M machines, their real position within the build volume is unknown. One goal of a repair process is to minimize the offset between the base component and the additively manufactured structure to reduce additional rework. For a minimum offset between component and additively manufactured structure, the actual position of the component has to be identified with high precision within the machine coordinate system (MCS). In this work a process setup is presented that allows the actual position of a gas turbine blade to be detected inside a PBF-LB/M machine. A high resolution camera with 65 megapixel is used for this purpose. The presented setup is implemented on a SLM 280 HL PBF-LB/M machine. In addition to the setup, a novel repair workflow using PBF-LB/M is presented. The developed setup and workflow consider inaccuracies in the component and camera mounting, as well as process inaccuracies. This includes keystone distortion correction by homography. The machine setup and workflow are used to repair a real gas turbine blade. Subsequently the offset between the turbine blade and the additivley manufactured structure is validated by 3D scanning the repaired part. The maximum offset is 160 µm. The presented approach can be extended to other geometries and PBF-LB/M machine manufacturers. The high-resolution camera approach is platform independent, which facilates the market penetration of PBF-LB/M repair processes. T2 - International Symposium Additive Manufacturing 2023 (ISAM 2023) CY - Dresden, Germany DA - 30.11.2023 KW - additive manufacturing KW - powder bed fusion of metals utilizing a laser beam KW - PBF-LB/M KW - hybrid repair KW - position detection KW - high-resolution camera PY - 2023 AN - OPUS4-59193 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -