aDDITIVe MaNUFaCTUrING OF BLIsKs UsING Laser MaTerIaL

Subject to alterations in specifications and other technical information. 06/2012.
1
ADDITIVE MANUFACTURING
OF BLISKS USING LASER
MATERIAL DEPOSITION
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using zoom optics so that a near-net-shape can be produced
even with a single-layer design, e.g. of the turbine blade.
To check the material properties, blade-like test structures are
being manufactured for tensile and fatigue tests on a BLISK
demonstrator (see figures). In another step the process is
tailored to an OEM component.
Task
Result
BLISKs are currently manufactured using a great deal of
Deposition rates of up to 3.5 kg/h can be achieved with track
material (material loss approx. 80 percent), energy and time by
widths of between 2 and 4 mm, and with material properties
means of 5-axis milling, which results in very high production
(investigated to date: tensile strength) close to those of cast
costs given the high-quality materials used. The aim is to
IN 718. A model blade can be built up with near-net-shape
develop a new manufacturing technology that significantly
within 2 minutes. The deposition rate achieved supports a
reduces the aforementioned losses as well as production costs.
tolerance of +/- 200 μm with a selected allowance of 500 μm
The additive manufacturing of BLISKs reduces these losses
in relation to the geometry for the final machining process.
and offers a promising solution: material savings of around
60 percent and a reduction in the manufacturing time of some
Applications
30 percent are predicted over conventional processes. The
availability of the new additive manufacturing process ensures
Aerospace, in particular engine technology, is one application
(a) manufacturing that saves resources and, in turn, time and
area. Another area relates to wear and corrosion protection
money, (b) new design opportunities with no geometrical
for applications requiring high deposition rates coupled with
restrictions – designed for function, only – and (c) development
exacting shape-retention requirements.
of new, shorter, more efficient process chains.
Contacts
Method
Dipl.-Ing. Johannes Witzel, M. Eng.
Initially, process diagrams are being developed which
Phone +49 241 8906-535
document parameter windows for significantly increased
[email protected]
deposition rates for a selected material (e.g. IN 718). To this
end, parameter studies with laser output powers up to 10 kW
Dr. Andres Gasser
are being conducted. The track widths can also be varied by
Phone +49 241 8906-209
[email protected]
1 Material deposition of test blades
on a BLISK demonstrator.
2 Innovative shielding of atmospheric gases
in material deposition.
82 Fraunhofer Institute for Laser Technology ILT, www.ilt.fraunhofer.de
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