Seminar: “Additive manufacturing, repair and salvage of turbo machinery components by Laser Metal Deposition”, Dr. Kelbassa CREOL 102 Friday, November 5, 2010 / 4:00-5:00pm
Akad. Oberrat Dr.-Ing. Ingomar Kelbassa
Vice and Academic Director, Lehrstuhl fuer Lasertechnik, RWTH Aachen University
Turbo machinery components such as blade integrated disks (BLISKs) and nozzle guide vanes (NGVs) made from Nickel and Titanium base alloys such as Inconel 718, Ti-6Al-4V, Ti-6246, Ti-17, Mar-M247 and CMSX-4 are predestinated for repair and salvage operations due to their high value.
Currently these components are manufactured by time and cost intensive process chains containing processing steps such as casting, forging, milling, linear friction welding, thermal spraying etc.
The laser additive manufacturing process Laser Metal Deposition (LMD) offers new effective entire process chains by decreasing the number of processing steps as well as by enabling emerging applications for specific process steps. Parts can be repaired which were formally classified as non-repairable and components can be manufactured additively by new process chain designs and new processes.
This talk addresses the pathways from feasibility studies over process developments yielding in certified processes and industrially implemented machines. For BLISK manufacturing the single blades are directly manufactured additively on the disk by LMD. The significant increase of the deposition rate combined with a near-net-shape deposition is realized by the use of up to 10 kW laser power and the first application of a newly-designed LMD head with an integrated zoom-optics. The achievable metallurgical, mechanical - static and dynamic mechanical properties - and geometrical results, the implemented process chains including CAD/CAM/NC-coupling are presented and discussed.
Akad. Oberrat Dr.-Ing. Ingomar Kelbassa has studied mechanical engineering at RWTH Aachen University and has been working in the field of Laser Materials Processing at Fraunhofer ILT and Lehrstuhl fuer Lasertechnik (LLT), RWTH Aachen University, since 2000. His experience gained is shown by approx. 50 scientific publications. Since mid 2006 Ingomar Kelbassa is Vice and Academic director of LLT as well as he is involved in the acquisition of large-scale projects at Fraunhofer ILT.
For More Information:
Dr. Ilya Mingareev
Townes Laser Institute, CREOL
Phone: 1 (407) 823 6042