A Stepwise Development Process for Verifying the Integrity of Additively Manufactured Components
South Stage

A Stepwise Development Process for Verifying the Integrity of Additively Manufactured Components

Optimisation
Wednesday, Jun 8, 2022
10:30 AM - 11:00 AM | Europe/London

Presentation

English
About
To validate the performance of an additively repaired fan rotor, a structural integrity process uses a stepwise assessment that treats the component as a new design. The two laser DED additive repair processes under assessment are wire fed and blown powder. Validating the performance requires a series of tests and associated models for four steps: laboratory specimens, subcomponents, components, and the entire engine system. Considering the potential and likelihood of certain failure modes, the series of tests at each step vary in the material performance being assessed. Experimentation on laboratory specimens acquire properties such as tensile strength, elongation, low cycle fatigue (LCF), high cycle fatigue (HCF), crack growth rate, and fracture toughness. Subcomponent test articles fabrication occurs by sectioning an operational IBR into individual blades for vibration HCF assessment. Component level testing focuses on LCF and overspeed strength acquired from spin rig testing. The full turbine engine system with the rotor mainly focuses on HCF, which many consider the most critical mode of failure, and the engine performance. The proposed talk aims to walk through the steps, the results, and the implemented decision gates that allowed for validation of the additively repaired component.