Goodrich Aerostructures Group

Goodrich is a leading supplier of systems and equipment to the global aerospace industry. www.goodrich.com

Teradyne, Inc., Assembly Test Division

Teradyne's Assembly Test Division is engaged in the production, sales, and support of automatic test equipment for the electronics manufacturing industry.  www.teradyne.com

 

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Recently Completed Project:

Laser Engineered Net Shaping^TM Solutions (LENS^TM) for Commercial and Defense Applications

To extend the life of aging aircraft, combat vehicles, artillery and small arms for the Department of Defense (DoD), the need for more sophisticated repair and overhaul techniques are required. This includes improving existing methods, as well as developing new ones to enhance repair capabilities. Components such as turbine blades, vanes, impellers, stator assem­blies, rotating air seals, etc. are just a few types of the components requiring repair and overhaul using the latest technologies to extend system life due to the effects of corrosion, fatigue and stress.

The performance and reliability of these components and assemblies are critical to ensure that military assets are combat ready to assure mission success. For some parts, a hard facing layer may provide an adequate repair solution. However, many other components, made from difficult to process materials, require more complicated repair processes. These repairs can involve three-dimensional features, radial-oriented structures and directionally-solidified or single-crystal materials.

In a similar vein, the commercial industrial sector is re-evaluating its ability to manufacture and re-manufacture critical components based on the new capabilities provided by emerging technologies. Automotive engine manufacturers have determined that the make versus repair scenario for complex and costly engine valves substantiate the repair solution as much more attractive. Furthermore, major original equipment manufacturer’s (OEM’s) are considering ways in which to manufacture high tolerance parts that require surface buildup without the hazard associated with traditional heat affected zone processing.

Many of today’s current repair procedures do not lend themselves to automated operations. Manual operations such as tungsten inert gas (TIG) welding can add several variables into the repair process which could effect the quality and the cost of the finished product. Variables such as operator performance and fatigue can have a direct effect on rework and reliability. The lack of in-situ process controls affects repeatability, requiring additional post processing. The cost of additional personnel to perform these manual repair operations translates to higher costs. The speed at which the repair is performed directly affects combat readiness.

Developed at Sandia National Laboratories, Optomec’s Laser Engineered Net Shaping^TM (LENS^TM) direct metal deposition system provides a cost effective solution to reduce repair cycles and provide higher quality parts versus traditional repair methods. A high-powered laser beam (cwNd:YAG) is focused onto a part where metallic powder is injected under computer guidance to buildup three-dimensional layers, until the part repair is complete.

The LENS^TM process produces fully dense material, which eliminates the need for heat treating for many applications. Due to the rapid solidification that occurs during processing, superior strength and ductility is achieved for most metal alloys. The LENS^TM process is done in an inert atmosphere which can be operated unattended for extended periods of time. The same system can be used for repair, hard facing and three-dimensional part fabrication.

This project produced a commercialized version of the LENS^TM equipment and proceeded to determine both technical and economic feasibility on commercial and military applica­tions. On the commercial side, numerous process parameters based on part geometry and material were developed and catalogued to be used for future applications. The same was true on the military side but, in addition, there were cost avoidance targets to be met. The cost avoidance targets were exceeded by approximately 14% resulting in an annual cost avoidance in excess of $6M at the Anniston Army Depot (ANAD). Because of this success, ANAD will expand the intended applications of this technology to capture even greater cost avoidance.

For further information, contact the NCMS Program Manager, Mike Gnam,(734)995-4971