Defect free repair of blisks using additive manufacturing with wire feedstock

Important results from the project

The goal of the project has been to evaluate a so-called MIMO (multiple input, multiple output) control system where input from two different measurement sensors is merged together to control two different quantities in the AM process in a more robust way than before. The overall goal has been achieved and demonstrated in industrial-grade AM equipment to TRL3. In the long term, these results will enable the repair of fine-scale critical components such as turbine blades in an aeroengine.

Expected long term effects

Qualified AM will provide increased design freedom towards e.g. higher operating temperature, longer life or lighter weight. Such benefits not only improve the performance of the end product, but also reduce the environmental impact throughout the product´s life cycle and lower the threshold for e.g. electrification of aviation. Local processing will also be possible due to the reduced need for e.g. larger forgings, which ensures a resilient and robust Swedish production technology ecosystem.

Approach and implementation

The project was divided into 5 work packages; System design of the MIMO system, Upgrade of the printhead, Integration of the sensor hardware, Validation tests and Project admin. After an initial delay due to limited access to the robot cell (and an extension of the project) the project continued according to plan. The collaboration between Procada and University West worked very well and Production Technology Center in Trollhättan has the right infrastructure for relevant validation tests.