Making serial parts out of metal powder
Complex-shaped components in aircraft engines can be produced quickly and at a reasonable price using selective laser melting (SLM).
The potential of selective laser melting has been demonstrated by researchers at the Fraunhofer Institute for Laser Technology ILT in the EU-sponsored FANTASIA project.
This has been demonstrated by researchers at the Fraunhofer Institute for Laser Technology ILT in the EU-sponsored FANTASIA project. “With this process we can not only make perfect repairs to damaged engine parts but also build complete components that cannot be produced using conventional methods such as milling or casting,” observes Dr. Konrad Wissenbach of ILT.
“This also permits the kinds of geometries and designs we once could only dream of.” Indeed, the figures speak for themselves: with this and other laser-based generative methods, manufacturing cycle times can be reduced by 40 percent or more. In the future, this will mean savings of up to 50 percent of the material required, and at least 40 percent of repair costs. Wissenbach is coordinator of the 6.5 million euro, EU-sponsored FANTASIA project – an acronym standing for “Flexible and near-net-shaped generative manufacturing chains and repair techniques for complex shaped aero engine parts.” The SLM approach is not suitable for every turbine material just yet.
“We have already seen very good results with Inconel 718, a nickel-based superalloy, and with titanium alloys as well,” Wissenbach remarks. “We are not quite as far along with other fissure-prone materials.” Here, ILT researchers are continuing the search for ways of using melting or molding to reseal any cracks a part may have developed during use. Of course it would be even better if cracking could be prevented altogether. This is why the engineers are experimenting with different parameters, varying laser output power, beam geometry and the structure strategy. They are also investigating the effects of construction-platform preheating on product quality.
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