Inconel Blisk Repair by Laser Deposition

Integrally Bladed Rotors (IBRs) are important in the design of modern aircraft engines. They offer attractive performance benefits, but due to their expense they require robust repair schemes, in order to avoid costly replacement during overhaul. The Laser Engineered Net Shaping (LENS) process has demonstrated repair of IBRs without compromising mechanical integrity. LENS is an additive manufacturing technique, where the original material, in this case Inconel, is deposited in the repair area to achieve a full metallurgical bond, with properties often approaching those of the original material. In this work we will develop a repair for an Inconel blisk airfoil that has suffered Foreign Object Damage or wear. In Phase I we investigated methods to achieve the required microstructure and soundness from the LENS-deposited Inconel. We also investigated methods to understand and control the deposition process. In the Phase I option, we will refine the processes, and test the properties of the materials. In Phase II, we will develop and demonstrate the repair process, and through a Phase II Option, bring the LENS repair process toward production readiness.