On the challenges of hybrid repair of gas turbine blades using laser powder bed fusion
- Additive manufacturing (AM) processes such as laser powder bed fusion (PBF-LB/M) are rapidly gaining popularity in repair applications. Gas turbine components benefit from the hybrid repair process as only damaged areas are removed using conventional machining and rebuilt using an AM process. However, hybrid repair is associated with several challenges such as component fixation and precise geometry detection. This article introduces a novel fixturing system, including a sealing concept to prevent powder sag during the repair process. Furthermore, a high-resolution camera within an industrial PBF-LB/M machine is installed and used for object detection and laser recognition. Herein, process related inaccuracies such as PBF-LB/M laser drift is considered by detection of reference objects. This development is demonstrated by the repair of a representative gas turbine blade. The final offset between AM build-up and component is analysed. An approximate accuracy of 160 μm is achieved withAdditive manufacturing (AM) processes such as laser powder bed fusion (PBF-LB/M) are rapidly gaining popularity in repair applications. Gas turbine components benefit from the hybrid repair process as only damaged areas are removed using conventional machining and rebuilt using an AM process. However, hybrid repair is associated with several challenges such as component fixation and precise geometry detection. This article introduces a novel fixturing system, including a sealing concept to prevent powder sag during the repair process. Furthermore, a high-resolution camera within an industrial PBF-LB/M machine is installed and used for object detection and laser recognition. Herein, process related inaccuracies such as PBF-LB/M laser drift is considered by detection of reference objects. This development is demonstrated by the repair of a representative gas turbine blade. The final offset between AM build-up and component is analysed. An approximate accuracy of 160 μm is achieved with the current setup.…
Autor*innen: | Benjamin MerzORCiD, Konstantin Poka, R. Nilsson, Gunther MohrORCiD, Kai HilgenbergORCiD |
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Dokumenttyp: | Beitrag zu einem Tagungsband |
Veröffentlichungsform: | Graue Literatur |
Sprache: | Englisch |
Titel des übergeordneten Werkes (Englisch): | Lasers in Manufacturing (LiM) 2023 |
Jahr der Erstveröffentlichung: | 2023 |
Organisationseinheit der BAM: | 9 Komponentensicherheit |
9 Komponentensicherheit / 9.6 Additive Fertigung metallischer Komponenten | |
Erste Seite: | 1 |
Letzte Seite: | 9 |
DDC-Klassifikation: | Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten |
Freie Schlagwörter: | Additive manufacturing; High-resolution camera; Hybrid repair; Laser powder bed fusion; Position detection |
Themenfelder/Aktivitätsfelder der BAM: | Material |
Material / Additive Fertigung | |
Veranstaltung: | LiM 2023 |
Veranstaltungsort: | Munich, Germany |
Beginndatum der Veranstaltung: | 26.06.2023 |
Enddatum der Veranstaltung: | 29.06.2023 |
Verfügbarkeit des Dokuments: | Datei im Netzwerk der BAM verfügbar ("Closed Access") |
Datum der Freischaltung: | 05.07.2023 |
Referierte Publikation: | Nein |