Fatigue Enhanced Weld Restoration of Titanium (Ti) Integrally Bladed Rotors (IBR)/Blisks

The latest generation of military turbine engines incorporate integral bladed rotors (IBRs or Blisks) in the high and low compression sections to improve performance and reduce part count. However, when damaged, IBRs offer a unique challenge to repair and restore to engine service. This proposed program offers to address this unique repair challenge to dimensionally restore IBR blades with microstructures and mechanical properties that approach near parent metal. This innovative repair process utilizes localized metal deposition and thermal mechanical working techniques as well as localized heat treatment methods to restore the IBR blade to service. Emphasis will be placed on demonstrating affordable repair methods guided by value stream analysis and cost modeling to ensure the development effort focuses on reduction of the process cost drivers while obtaining the desired dimensional and metallurgical restoration of the IBRs. BENEFITS: IBRs are expensive components, development of affordable methods to return these components to service is considered to be very beneficial to the Navy and other DoD agencies. Additionally, the repair techniques demonstrated during this program will be of benefit to commercial and industrial gas turbine engines.