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Item type:Publication, Access status: without files , LMDCAM, computer aided manufacturing (CAM) solution for tool path generation for build-up of complex aerospace components by laser metal deposition (LMD)(Old City Publishing, 2014-01-01); ; ; ; The success of laser metal deposition (LMD) for repair or fabrication of near-net shaped metals components directly from computer aided design (CAD) solid models without use of time and cost-prohibitive conventional techniques, such as five-axis milling, linear friction welding and electro chemical machining depends on the availability of a close CAD/ computer aided manufacturing (CAM) chain. Distortion and defects of a worn part implies that the nominal CAD model from the design stage is no longer suitable for the representation of the part geometry. This means that first of all the actual and the target geometry have to be constructed from which the deficit volume is determined. Only with this volume being available the tool paths can be programmed. The original data format of laser scanned data is a polygonal modelling approach for surface representation. The further step of creating a non-uniform rational B-spline (NURBS) representation of the geometry requires a major commitment in time, both in instruction and in amount of work. For this reason the Fraunhofer Institute for Laser Technology (ILT) designed a process chain for the laser material deposition (LMD) whose CAM module termed LMDCAM, is based on a polygonal modelling approach for geometry representation. NURBS are only used for the reduction of data noise in the scanned data. The target geometry of worn parts is derived by a best fit with the CAD model from the design stage. LMDCAM supports the generation of all sorts of path pattern within a layer which for example may be derived from a distortion reduction analysis. The functionalities of LMDCAM are exemplified by a repair application and the near-net fabrication of a blade-integrated disk (BLISK) blade direct from the CAD model.Publicationtype: Journal Article31 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , LACAM3D, CAM solution for tool path generation for build up of complex aerospace components by laser powder deposition(Springer, 2012-07); ; ; ; This The success of Laser Metal Deposition (LMD) for repair or fabrication of near-net shaped metals components directly from CAD solid models without use of time and cost-prohibitive conventional techniques, such as five-axis milling, linear friction welding and electro chemical machining depends on the availability of a close CAD/CAM chain. Distortion and defects of a worn part implies that the nominal CAD model from the design stage is no longer suitable for the representation of the part geometry. This means that first of all the actual and the target geometry have to be constructed from which the deficit volume is determined. Only with this volume being available the tool path programmed. The original data format of laser scanned data is a polygonal modeling approach for surface representation. The further step of creating a NURBS representation of the geometry requires a major commitment in time, both in instruction and in amount of work. For this reason the ILT designed a process chain for the LMD whose CAM module, LACAM3D, is based on a polygonal modeling approach for geometry representation. NURBS are only used for the reduction of data noise in the scanned data. The target geometry of worn parts is derived by a best fit with the CAD model from the design stage. LACAM3D supports the generation of all sorts of path pattern within a layer which for example may be derived from a distortion reduction analysis. The functionalities of LACAM are exemplified by a repair application and the near-net fabrication of a BLISK (Blade-Integrated diSK) blade direct from the CAD model.Publicationtype: Conference Paper28 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Additive manufacturing of a blade-integrated disk by laser metal deposition(Laser Inst. of America, 2011-10); ; ; Currently, high value Class 1 jet engine components such as BLISKs (Blade-Integrated diSKs) are manufactured by time and cost-prohibitive conventional techniques, such as five-axis milling, linear friction welding and electro chemical machining. The investigation within the Fraunhofer Cluster of Innovation "TurPro" qualifies Laser Metal Deposition (LMD) as a new "green manufacturing" method for nickel and titanium alloy-based BLISKs. Feasibility studies and subsequent process development towards a first additive IN 718 BLISK mock-up are presented. Parameter windows for laser powers up to 10 kW have been investigated to attain high deposition rates of up to 9,000 mm3/min for track widths between 2 mm and 4 mm. Using a zoom optics, track width of the tool path can be adjusted during the process to the airfoil geometry and a near-net shape built up can be achieved. Process time of two minutes for the additive manufacture of a near-net shape single blade was achieved. When the blade receives the appropriate heat treatment, its static and dynamic material properties were found to be approximate to forged components.Publicationtype: Conference Paper14 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Characterization of micro/macrostructure of laser cladded inconel 718 with increased deposition rates as related to the mechanical properties(Laser Inst. of America, 2011-10); ; ; Currently, high value Class 1 jet engine components such as BLISKs (Blade Integrated DiSKs) are manufactured by time and cost-prohibitive conventional techniques, such as five-axis milling, linear friction welding and electro chemical machining. This project within the Fraunhofer Cluster of Innovation "TurPro" qualifies the LMD process as a new "green manufacturing" method for nickel and titanium alloy-based BLISKs. Quality assurance and predictable material properties remain a major concern when aiming for a process certification of additive manufacturing of BLISK blades. This paper presents the results of a microstructure investigation of laser cladded IN 718 using increased deposition rates of up to 7000 mm3/min. Presented are the ternary relations between process parameters, dendrite arm spacing and resulting mechanical properties with respect to niobium segregation.Publicationtype: Conference Paper12 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Development of a model for prediction of material properties of laser cladded inconel 718 as related to porosity in the bulk material(Laser Inst. of America, 2011-10); ; ; High value jet engine components such as compressor blades or BLade Integrated DiSKS (BLISKS) are manufactured by time and cost-prohibitive conventional techniques, such as five-axis milling, linear friction welding and electro chemical machining. This project within the Fraunhofer Cluster of Innovation "TurPro" qualifies the Laser metal deposition process (LMD) as a new "green manufacturing" method for nickel and titanium alloy-based BLISKs. Thus, a significant increase of the deposition rate (factor 10 or higher) is of interest. Aiming for a process certification of additive manufacturing of BLISK blades, using conventionally manufactured disks as a substrate, quality assurance and predictable material properties remain a major concern. In this paper, the distribution of pore sizes of laser deposited Inconel 718 (IN 718) is investigated, using laser powers of up to 5.5 kW and deposition rates of up to 7000 mm3/min. Using quantitative image analysis, defining sub-sets and applying extreme value and logarithmic Gaussian distribution, the pore-size-distribution in the bulk material can be described with merely 4 statistical parameters. Based on these parameters, the ultimate tensile strength (UTS) of a cladded sample can be estimated with an accuracy of approx. 250 - 300 MPa.Publicationtype: Conference Paper14 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Increasing the deposition rate of inconel 718 for LMD(Laser Inst. of America, 2010-09); ; ; Laser Metal Deposition (LMD) is beneficial when applying repairs on components of high complexity such as compressor blades or BLade Integrated diSKS ("BLISKS"). Due to limited deposition rates, the process time for LMD is increased which is a main factor for high production costs. Thus, a significant increase of the deposition rate (factor 10 and higher) is of interest when using LMD for repair and for additive manufacture of entire parts. Goal of the current study is the qualification of LMD as a production and repair process for high-speed repair and additive manufacture of compressor blades and BLISKs made of IN 718 using conventional manufactured disk as a substrate. In a first step studies on appropriate processing parameter combinations for higher deposition rates are carried out using a 10 kW disk laser system. Two strategies are currently examined when building-up single blades. A coaxial powder feeding nozzle is assembled to a zoom optic and guarantees a near-net-shape deposition while a lateral square-shaped powder feeding nozzle together with square shaped laser beam geometry provides higher deposition rates. In a second step, LMD of a blade mock-up is carried out using a variation of the laser beam diameter during the process.Publicationtype: Conference Paper21