AMOS is investigating a number of additve manufacturing (AM) processes which can be used for repair of aerospace components such as turbine blades and landing gears. Damaged components can be repaired (on-demand) and material lost in service can also be re-deposited to restore the component to its original shape. This approach has the potential to reduce lead times, cost and material waste and to extend the service life of damaged or worn components.

The partners will carry out fundamental research to understand the resultant material properties of a number of direct energy deposition (DED) processes for three different materials. They will investigate the accuracy and limitations of these deposition processes, effective defect geometry mapping and generation methods, and automated and hybrid DED and post-deposition machining strategies. Both powder- and wire-based DED systems will be investigated to establish an across-the-board comparative study. The data collected will be extremely valuable for the large companies who are partners in this project (GKN, PWC, and HDI) allowing them to understand the pros and cons of these systems and helping them to select suitable repair and re-manufacturing additive technologies. The tests conducted in this research are also extremely beneficial for the SMEs in this project (Liburdi and DPS) to validate and improve their existing repairing systems and techniques.

Common additive processes are typically controlled either by a CNC controller or a robotic controller depending on the type of machine that carries the deposition nozzle system. Therefore, both CNC and robotic systems will be studied for both powder and wire feedstock using lasers or Tungsten welding as a power source. A number of aerospace alloys will be investigated, including Ti-6Al-4V and Inconel 718.

The specific objectives are to:

  • Study the process accuracy, repeatability, limitations and material integrity of the different systems under consideration
  • Develop an effective system to generate the repair geometry
  • Develop accuracte models to simulate the different deposition processes
  • Develop a method to optimise component design for additive repair
  • Establish the qualification procedure to allow suitable technologies to be used for repair and remanufacture

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