Fraunhofer-Institut für Lasertechnik ILT
The additive manufacturing process laser powder bed fusion (LPBF) is already being used on an industrial scale for the small series production of highly complex shaped components. Recent research activities increasingly focus on so called hybrid additive manufacturing processes, where layer-by-layer remelting takes place starting from a conventionally manufactured preform body that serves as the base plate. In principle, this manufacturing method can reduce production costs and process times, as the costly and time-consuming LPBF manufacturing process is only used for critical component areas or functional surfaces. In addition, hybrid additive manufacturing enables the repair of components (e.g. turbine blades or tools), which can significantly improve both the ecological and economic balance of component production. In order to ensure the functionality of the overall component, both defect free metallurgical bonding and an offset-free connection within the interface between the component areas are crucial. Experimental studies with nickel-base alloy Inconel®718 were conducted on a commercial machine setup equipped with a camera based preform detection system. In a first step, the preform detection accuracy is evaluated using specimen with distinct geometrical features such as thin walls and sharp contour angles. Hybrid manufactured tensile specimen, consisting of wrought Inconel®718 preform material, are manufactured at three different base plate temperatures room temperature, 200 °C and 500 °C. Light optical metallographic analysis reveal an almost defect free bonding interface. Mechanical stresses between comparable to fully additively manufactured specimens are measured for yield strength (YS) and ultimate tensile strength (UTS), respectively. Finally, a proof of concept of the developed processing strategy is performed via the use case of turbine blade tip repair and specific challenges regarding accurate referencing of freeform geometries are presented.
Abstract
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