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Research Papers

Technology-Based Recontouring of Blade Integrated Disks After Weld Repair

[+] Author and Article Information
Berend Denkena

Institute of Production Engineering
and Machine Tools (IFW),
Leibniz Universität Hannover,
An der Universität 2,
Garbsen 30823, Germany
e-mail: denkena@ifw.uni-hannover.de

Arne Mücke

Institute of Production Engineering
and Machine Tools (IFW),
Leibniz Universität Hannover,
An der Universität 2,
Garbsen 30823, Germany
e-mail: muecke@ifw.uni-hannover.de

Tim Schumacher

Institute of Production Engineering
and Machine Tools (IFW),
Leibniz Universität Hannover,
An der Universität 2,
Garbsen 30823, Germany
e-mail: schumacher@ifw.uni-hannover.de

Demian Langen

Institute of Materials Science (IW),
Leibniz Universität Hannover,
An der Universität 2,
Garbsen 30823, Germany
e-mail: langen@iw.uni-hannover.de

Thomas Hassel

Institute of Materials Science (IW),
Leibniz Universität Hannover,
An der Universität 2,
Garbsen 30823, Germany
e-mail: hassel@iw.uni-hannover.de

1Corresponding author.

Manuscript received June 22, 2018; final manuscript received June 28, 2018; published online November 20, 2018. Editor: Jerzy T. Sawicki.

J. Eng. Gas Turbines Power 140(12), 121015 (Nov 20, 2018) (8 pages) Paper No: GTP-18-1277; doi: 10.1115/1.4040738 History: Received June 22, 2018; Revised June 28, 2018

The widespread adoption of blade integrated disks (blisks) made of titanium demands tailored regeneration processes to increase sustainability and economic efficiency. High standards regarding geometrical accuracy and functional properties as well as the unique characteristics of each type of damage complicate the repair. Thus, flexible and well-designed processes are necessary. Typically, material deposit is followed by a milling or grinding process to restore the original shape. Here, the individual repair processes not only have to be controlled but also their interaction. For example, depending on the resulting microstructure of the welded seam, the recontouring process needs to be adapted to minimize tool wear as well as shape deviations of the complex blade geometries. In this paper, the process chain for a patch repair is examined, consisting of a tungsten inert gas (TIG) welding process followed by five-axis ball nose end milling. Conventional TIG as well as a modified TIG process producing a finer grain structure and enhanced mechanical properties of deposited material was investigated. Grain refinement was achieved by SiC particles added to the weld pool. Based on the characteristics of the fusion material and static stiffness of the component, a methodology is introduced to minimize shape deviation induced by the subsequent milling process. Special attention is given to tool orientation, which has a significant impact on the kinematics and resulting process forces during milling. An electromagnetic guided machine tool is used for compensation of workpiece deflection.

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Figures

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Fig. 1

Process chain for a typical repair

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Fig. 2

Macro- (a) and micrograph (b) of weldment in cross-sectional view (without SiC addition)

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Fig. 3

Macro- (a) and micrograph (b) of weldment in cross-sectional view (with SiC addition, 3.4 wt % Si)

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Fig. 4

Microhardness of a TIG welded specimen

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Fig. 5

Microhardness of a TIG welded specimen with SiC addition (3.4 wt % Si)

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Fig. 6

Five-axis ball end milling parameters

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Fig. 7

Process forces for milling of TIG and TIG + SiC welds

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Fig. 8

Force coefficients for TIG and TIG + SiC weld

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Fig. 9

Process forces for different λi

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Fig. 10

Max. passive force Fp,max (left) and max. resultant force Ff,fn,max.

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Fig. 11

Force coefficients for λ = var., τ = 0 deg

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Fig. 12

Methodology for process design of recontouring

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Fig. 13

Neximo: five-axis milling machine with electromagnetic guide

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Fig. 14

Test workpiece and clamping

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Fig. 15

Signal processing

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Fig. 16

Block diagram for displacement compensation

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Fig. 17

Local workpiece stiffnesses and displacement

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Fig. 18

Calculated workpiece deflection

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Fig. 19

Recontoured patch area with and without compensation

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