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Laser
Engineered Net Shaping Solutions (LENS)TM
for Commercial and Defense Applications
Both the military and the commercial industrial sectors are
re-evaluating their ability to manufacture and re-manufacture critical
components based on the new capabilities provided by emerging
technologies. More sophisticated repair and overhaul (R&O) techniques
are required. The LENSTM
process produces fully dense material, which eliminates the need for
heat treating for many applications. The same system can be used for
repair, hard facing and three-dimensional part fabrication. The LENSTM
850R system is being enhanced with key features to satisfy the stringent
requirements of the R & O market.
This is a follow-on project to the successful
LENSTM
I project which demonstrated the technical feasibility and the economic
benefits of this repair technology to depot level maintenance.
Laser Engineered Net ShapingTM
Solutions (LENSTM) 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 ShapingTM (LENSTM) 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 LENSTM 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 LENSTM 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 LENSTM 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.
Program Manager: Mike Gnam, (734) 995-4971,
mikeg@ncms.org
TM
LENS is a registered trademark of Sandia National Laboratories.
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