Reconditioning of nickel base HPT blades and vanes used in aero engines and power plant gas turbines by combination of direct laser forming, laser metal deposition and laser drilling

2006 ◽  
Author(s):  
Ingomar Kelbassa ◽  
Ernst Wolfgang Kreutz ◽  
Christoph Over ◽  
Lena Trippe ◽  
Konrad Wissenbach
Keyword(s):  
Power Plant ◽  
Gas Turbines ◽  
Laser Drilling ◽  
Metal Deposition ◽  
Laser Forming ◽  
Laser Metal Deposition ◽  
Direct Laser ◽  
Aero Engines ◽  
Nickel Base

Laser Metal Deposition Shaping System for Direct Fabrication of Parts

2011 ◽  
Vol 66-68 ◽  
pp. 2202-2207 ◽  
Author(s):  
Kai Zhang ◽  
Xiao Feng Shang ◽  
Wei Jun Liu
Keyword(s):  
Control System ◽  
Laser Beam ◽  
Molten Pool ◽  
Metal Deposition ◽  
Laser Forming ◽  
Laser Metal Deposition ◽  
Small Stream ◽  
Metal Parts ◽  
Direct Laser ◽  
Computer Aided

The fabrication of metal parts is the backbone of the modern manufacturing industry. Laser forming is the combination of five common technologies: lasers, rapid prototyping (RP), computer-aided design (CAD), computer-aided manufacturing (CAM), and powder metallurgy. The resulting process creates part by focusing an industrial laser beam on the surface of processing workpiece to create a molten pool of metal. A small stream of powdered alloy is then injected into the molten pool to build up the part gradually. By moving the laser beam back and forth and tracing out a pattern determined by a CAD, the solid metal part is fabricated line by line, one layer at a time. By this method, a material having a very fine microstructure due to rapid solidification process can be produced. In the present work, a type of direct laser deposition process, called Laser Metal Deposition Shaping (LMDS), has been employed and developed to fabricate metal parts. The LMDS apparatus consists of four primary components: energy supply system, motion control system, powder delivery system, and computer control system. These components have their specified functions, but work in association with each other.

The Effect of High Temperature on the Degradation of Heat-Resistant and High-Temperature Alloys

2009 ◽  
Vol 147-149 ◽  
pp. 744-751 ◽  
Author(s):  
Józef Błachnio
Keyword(s):  
High Temperature ◽  
Mechanical Strength ◽  
Gas Turbines ◽  
Base Alloy ◽  
Heat Resistant ◽  
High Temperature Materials ◽  
High Temperature Alloys ◽  
Aerospace Technology ◽  
Aero Engines ◽  
Nickel Base

Heat-resistant and high-temperature materials are used to manufacture components, devices, and systems operated at high temperatures, i.e. under severe heat loads. Gas turbines used in the power industry, the traction, marine, and aircraft engines, the aerospace technology, etc. are good examples of such systems. Generally, as the temperature increases, the mechanical strength of materials decreases. While making such materials, there is a tendency to keep possibly low thermal weakening. In the course of operating gas turbines, various kinds of failures/defects/ damages may occur to components thereof, in particular, to blades. Predominating failures/damages are those attributable to the material overheating and thermal fatigue, all of them resulting in the loss of mechanical strength. The paper has been intended to present findings on changes in the microstructure of blades made of nickel-base alloy due to high temperature. The material gets overheated, which results in the deterioration of the microstructure’s condition. The material being in such condition presents low high-temperature creep resistance. Any component, within which such an effect occurs, is exposed to a failure/damage usually resulting in the malfunctioning of the turbine, and sometimes (as with aero-engines) in a fatal accident. Failures/damages of this kind always need major repairs, which are very expensive.

scholarly journals A monitoring framework based on exergetic analysis for sustainability assessment of direct laser metal deposition process

2021 ◽  
Author(s):  
Valeria Selicati ◽  
Marco Mazzarisi ◽  
Francesco Saverio Lovecchio ◽  
Maria Grazia Guerra ◽  
Sabina Luisa Campanelli ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Sustainability Assessment ◽  
Metal Deposition ◽  
Process Efficiency ◽  
Laser Metal Deposition ◽  
Sustainable Solutions ◽  
Direct Laser ◽  
Monitoring Framework ◽  
Exergetic Analysis ◽  
Direct Laser Metal Deposition

Abstract With the constant increase of energy costs and environmental impacts, improving the process efficiency is considered a priority issue for the manufacturing field. A wide knowledge about materials, energy, machinery, and auxiliary equipment is required in order to optimize the overall performance of manufacturing processes. Sustainability needs to be assessed in order to find an optimal compromise between technical quality of products and environmental compatibility of processes. In this new Industry 4.0 era, innovative manufacturing technologies, as the additive manufacturing, are taking a predominant role. The aim of this work is to give an insight into how thermodynamic laws contribute at the same time to improve energy efficiency of manufacturing resources and to provide a methodological support to move towards a smart and sustainable additive process. In this context, a fundamental step is the proper design of a sensing and real-time monitoring framework of an additive manufacturing process. This framework should be based on an accurate modelling of the physical phenomena and technological aspects of the considered process, taking into account all the sustainability requirements. To this end, a thermodynamic model for the direct laser metal deposition (DLMD) process was proposed as a test case. Finally, an exergetic analysis was conducted on a prototype DLMD system to validate the effectiveness of an ad-hoc monitoring system and highlight the limitations of this process. What emerged is that the proposed framework provided significant advantages, since it represents a valuable approach for finding suitable process management strategies to identify sustainable solutions for innovative manufacturing procedures.

Sign in / Sign up

Export Citation Format

Share Document