Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Additives Fertigungs-Duo erleichtert Sensorintegration

2021 , Uhlmann, Eckart , Polte, Julian , Neuwald, Tobias , Kersting, Robert , Brunner-Schwer, Christian

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Sensor integration in hybrid additive manufactured parts for real-time monitoring in turbine operations

2021 , Uhlmann, Eckart , Polte, Julian , Kersting, Robert , Brunner-Schwer, Christian , Neuwald, Tobias

Real-time monitoring of operation conditions such as tempeatures and vibrations enables efficiency enhancement for maintenance tasks. In energy industry monitoring of critical components such as turbine blades is essential for the operation safety. But the effective recording of critical process data is a challenging task due to the extreme operating conditions. With a hybrid processing approach combining two additive manufacturing technologies new classes of self-monitoring components become possible allowing data acquisition directly inside the component. Using the example of a turbine blade, the hybrid process chain is described. The turbine blade blank is produced via Laser Powder Bed Fusion (L-PBF) with channels for the integration of high temperature sensors. After integration cavities were closed by Laser Directed Energy Deposition (L-DED) followed by classical milling operations for part finishing. The data acquisition is integrated in state-of-the-art product l ifecycle monitoring (PLM) software to create a digital twin. Evaluation shows that temperature could be successfully monitored at conditions of Π= 550°C.

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Laser-plasma-cladding as a hybrid metal deposition-technology applying a SLM-produced copper plasma nozzle

2018 , Brunner-Schwer, Christian , Kersting, Robert , Graf, Benjamin , Rethmeier, Michael

Laser-Metal-Deposition (LMD) and Plasma-Transferred-Arc (PTA) are well known technologies which can be used for cladding purposes. The prime objective in combining LMD and PTA as a Hybrid Metal Deposition-Technology (HMD) is to achieve high deposition rates at low thermal impact. Possible applications are coatings for wear protection or repair welding for components made of steel. The two energy sources (laser and plasma arc) build a joint process zone and are configurated to constitute a stable process at laser powers between 0.4-1 kW (defocused) and plasma currents between 75-200 A. Stainless steel 316L serves as filler material. For this HMD process, a plasma Cu-nozzle is designed and produced by powder bed based Selective Laser Melting. The potential of the HMD technology is investigated and discussed considering existing processes. This paper demonstrates how the interaction of the two energy sources effects the following application-relevant properties: deposition rate, powder efficiency and energy input.

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