Metal 3D Printing for Gas Turbine Engine Component Repair

ABSTRACT: Optomec, Inc., in collaboration with Triumph Engine Control Systems and The Ohio State University, proposes to develop an additive metal manufacturing (AMM) process and techniques for the repair of TF33 (P & W JT3D) fuel pump housing as well as other similar components of interest with critical seal and bearing surfaces that wear in service. Optomec"s LENS systems have previously been equipped and demonstrated with deep bore heads that can reach into bores down to 2.5 inches in diameter, and can deposit metallic repair materials on complex geometries typical of fuel pump housings. Optomec"s LENS technology is used in a variety of high-performance metal deposition applications throughout defense and commercial industry, including repair of titanium blisks, building nickel base superalloys and steel components, and repairing aluminum components. Optomec has also previously processed aluminum alloy 4047 to repair tooling components and will apply this experience to the proposed project"s scope. BENEFIT: Benefits of this work will include the ability to repair fuel pump housings for a variety of industries, including both defense and commercial sectors; with excellent surface finish and dimensional accuracy; with qualified mechanical properties; and with improved lifetime enabled by the additive approach. Spin-off applications include all areas where additive manufacturing is being considered for component repair, such as aerospace, tooling and general industrial component repair.