Defect free repair of blisks using additive manufacturing with wire feedstock

Purpose and goal:

The purpose of the project is to develop a new system within additive manufacturing that will enable the repair of compressor blades in aircraft engines. The goal is to demonstrate a first prototype with the laser-wire Directed Energy Deposition method and show that an adequate repair method for blisks is possible without the risk of creating defects in the repaired area.

Expected results and effects:

A blisk combines turbine blades and a disk in a single component and can thereby lower the weight by up to 20% per turbine stage and increase the performance in an aeroengine by several percent. The disadvantage, however, is that if individual blades are damaged, the entire blisk must be scrapped because adequate repair methods are still lacking for the most critical areas on a turbine blade. A successful project would therefore enable greater use of blisks in future aircraft engines.

Approach and implementation:

The project is a collaboration between Procada and University West and is divided into five different work packages; System design based on Procada´s latest patent application for process feedback, Upgrade of existing printer head to also handle sub-millimeter deposition, Integration of the new control system in industrial AM equipment at PTC Innovatum, Validation tests and finally Administration and dissemination.