Flat Wire Deposition for In-situ Repair
NCMS Project #: 140355
Problem: Conventional powder or round wire laser metal deposition repair techniques do not allow for quality in-situ repair of fatigue cracks or corrosion surface damage of large components, especially the components with thin wall structures and when the needed repair is on vertical or overhead surfaces.
Benefit:
Phase I demonstrated that this low heat deposition process could successfully repair large parts with minimal deformation, superior metal grain structure, minimum porosity and potentially improved fatigue life compared to competing processes such as MIG/TIG welding and laser powder metal deposition processes. Materials used were limited to Titanium 6-4 and Titanium 6-4 casting alloys to determine feasibility.
- The production of on-site, in-situ, low-heat input repairs, cladding, fabrication or reinforcement of damaged large and small metal components. The ability of the flat wire deposition Mobile-PMD™ system to repair large components without costly enclosure of the component inside a vacuum or inert gas chamber, as is the case in other deposition processes
- The unique capability to repair components and fabricate integral strengthening ribs and bosses on thin wall forged or cast components
- Finally, Mobile-PMD™ system enabled the repair of parts previously considered non-repairable due to components’ size, shape. The capability of the PMDTM flat wire laser deposition process was successfully demonstrated for repair of surface damage on large and complex thin wall structures, curved surfaces of components as large as 4 to 5 feet in diameter such as a jet engine casing or thin wall titanium alloy exhaust pipe.
Solution/Approach: The Flat Wire project was designed in two phases, with a go/no-go decision point following a Phase I feasibility study after which additional funds would be sought for future work.
Phase I objectives were to:
- Develop an initial prototype for a mobile precision metal deposition (PMDTM) system
- Demonstrate its capability of performing basic repair operations on flat and curved surfaces.
DOD Participation:
- U.S. Air Force – Warner Robins ALC
- U.S. Navy – NUWC Keyport
- U.S. Navy – NADEP, Cherry Point
Industry Participation:
- H&R Technology, Inc. (HRT)
- Chromalloy Gas Turbine Corporation
- Precision Castparts Corporation
- Goodrich Aerostructures
- Boeing
- NCMS