Novel Hybrid Manufacturing Process of CM247LC and Multi-Material Blisks

Xiqian Wang,Nicholas J E Adkins,Moataz M Attallah,Khamis Essa,Luke N Carter

doi:10.3390/mi11050492

Abstract

The study on CM247LC used the traditional approach for Near-Netshape Hot Isostatic Pressing (NNSHIP) with sacrificial low carbon steel tooling, which was built using Selective Laser Melting (SLM), to produce a shaped CM247LC blisk. The assessment of the microstructure focused on both the exterior components in order to determine the depth of the Fe-diffusion layer and on the interior microstructure. Samples were extracted from the Hot Isostatic Pressed (HIPped) components for tensile testing at both room and elevated temperatures. The components were scanned to assess the geometrical shrinkages due to Hot Isostatic Pressing (HIPping). An oversized blisk was also produced based on the measurements as a demonstrator component. In addition, a further study was carried out on a novel idea that used a solid IN718 disk in the centre of the blisk to create a multi-material component.

Highlights

Additive Manufacturing (AM), as a netshape technology, has developed rapidly in the past 10 years
Near-Netshape HIPping (NNSHIP) of a CM247LC blisk component using steel tooling built via Selective Laser Melting (SLM) has been developed
Fe-tooling SLM/HIP of CM247LC was developed, and a can design which combines simple, mild steel ‘over-can’ tooling by machining with a complex blade tooling produced in low carbon steel by SLM successfully fabricated an oversized blisk

Summary

Introduction

Additive Manufacturing (AM), as a netshape technology, has developed rapidly in the past 10 years. Selective Laser Melting (SLM) is an AM process that uses a high intensity laser to selectively melt defined areas geometries layer by layer and allows the production of near netshape components directly from the metal powder [5,6,7,8,9]. CM247LC is a chemically modified version of the more common MAR M247. The improved performance of CM247LC is due to the modified elements from MAR M247 [10,11,12]. The castability, alloy ductility, fatigue strength and carbide stability of CM247LC DS have been improved compared with MAR M247 [13]. CM247LC DS samples possess the highest tensile strength at a various range of temperatures compared with IN6203 DS and IN792 DS samples [14]

Methods

Results

Conclusion