Additive manufacturing of a blade-integrated disk by laser metal deposition

Abstract

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.