Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Fraunhofer ILT wins Aviation Week 2012 Innovation Challenge for Additive Manufacturing of BLISKs

29.03.2012
The American magazine Aviation Week awards excellent solutions for the aerospace and defense (A&D) industry annually.
Sought-after are new developments, e.g., for sinking production costs and improving integration of innovative technologies. The team from the Fraunhofer Institute for Laser Technology ILT has won the 2012 Innovation Challenge in the category “Power and Propulsion” for its additive manufacturing process of BLISKs. Representing the entire team, Dr. Ingomar Kelbassa and Johannes Witzel received the award in Washington, D.C. on March 7, 2012.

Turbomachines form the heart of power plants and airplanes. As the need for energy and mobility grows, so too increases the demand for turbomachines as providers of energy. What is currently at stake is designing them in such a way that they produce more energy and less CO2 while using less fuel. Researchers at the Fraunhofer Institute for Production Technology IPT and the Fraunhofer Institute for Laser Technology ILT have made it their goal of implementing processes for the manufacture and maintenance of energy-efficient turbomachines. Together with the Fraunhofer Society and the German Federal State of North-Rhine Westphalia, they have called into life the Aachen Fraunhofer Cluster for Innovation “Integrative Production Technology for Energy-Efficient Turbomachines” with a total volume of 10.25 million Euros. Also part of the project are 16 industrial enterprises, among others global players such as MAN Diesel & Turbo, Siemens PG, Rolls-Royce Deutschland and MTU Aero Engines.

Preserving Resources and the Environment Intelligently

BLISKs are important components for aircraft engine and turbine construction, consisting of disks with integrated compressor blades. Currently BLISKs are produced with conventional manufacturing processes, e.g. five-axis milling, creating a great loss of material and use of energy and time, and causing very high production costs. Within the Fraunhofer Cluster for Innovation “TurPro” – in cooperation with Rolls-Royce Deutschland Ltd & Co KG as well as in partnership with the Fraunhofer IPT – the Fraunhofer ILT has developed a laser-based process that preserves resources during manufacture and maintenance of BLISKs.

In this process, a powder feed nozzle applies a layer of nickel or titanium-based alloy exactly where a blade should be formed on the disc with the highest precision. Then, the laser beam melts the powder and joins it with the underlying material. This way, a compressor blade can be built layer by layer. This additive manufacturing method, Laser Material Deposition LMD, is also suitable for maintaining components. Using the innovative manufacturing technology, the Aachen researchers have been able to save materials by up to 60 percent as compared to conventional processes and to shorten the overall manufacturing time by around 30 percent, all of which slashes the production costs of BLISKS significantly.

Contact Partners at Fraunhofer ILT
Our experts will be glad to any your questions:

Dr.-Ing. Ingomar Kelbassa, Academic and Vice Director
Chair for Laser Technology LLT, RWTH Aachen University
Fraunhofer Institute for Laser Technology ILT
Telephone +49 241 8906-143
ingomar.kelbassa@ilt.fraunhofer.de

Dipl.-Ing. Johannes Witzel, M. Eng.
Laser Material Deposition LMD
Telephone +49 241 8906-535
johannes.witzel@ilt.fraunhofer.de

Dr.-Ing. Andres Gasser
Group Leader Laser Material Deposition LMD
Telephone +49 241 8906-209
andres.gasser@ilt.fraunhofer.de

Fraunhofer Institute for Laser Technology ILT
Steinbachstraße 15
52074 Aachen, Germany
Tel. +49 241 8906-0
Fax. +49 241 8906-121

Axel Bauer | Fraunhofer ILT
Further information:
http://www.ilt.fraunhofer.de

More articles from Awards Funding:

nachricht The quest for the oldest ice on Earth
14.11.2016 | Alfred-Wegener-Institut, Helmholtz-Zentrum für Polar- und Meeresforschung

nachricht Empa Innovation Award for new flame retardant
09.11.2016 | Empa - Eidgenössische Materialprüfungs- und Forschungsanstalt

All articles from Awards Funding >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Significantly more productivity in USP lasers

In recent years, lasers with ultrashort pulses (USP) down to the femtosecond range have become established on an industrial scale. They could advance some applications with the much-lauded “cold ablation” – if that meant they would then achieve more throughput. A new generation of process engineering that will address this issue in particular will be discussed at the “4th UKP Workshop – Ultrafast Laser Technology” in April 2017.

Even back in the 1990s, scientists were comparing materials processing with nanosecond, picosecond and femtosesecond pulses. The result was surprising:...

Im Focus: Shape matters when light meets atom

Mapping the interaction of a single atom with a single photon may inform design of quantum devices

Have you ever wondered how you see the world? Vision is about photons of light, which are packets of energy, interacting with the atoms or molecules in what...

Im Focus: Novel silicon etching technique crafts 3-D gradient refractive index micro-optics

A multi-institutional research collaboration has created a novel approach for fabricating three-dimensional micro-optics through the shape-defined formation of porous silicon (PSi), with broad impacts in integrated optoelectronics, imaging, and photovoltaics.

Working with colleagues at Stanford and The Dow Chemical Company, researchers at the University of Illinois at Urbana-Champaign fabricated 3-D birefringent...

Im Focus: Quantum Particles Form Droplets

In experiments with magnetic atoms conducted at extremely low temperatures, scientists have demonstrated a unique phase of matter: The atoms form a new type of quantum liquid or quantum droplet state. These so called quantum droplets may preserve their form in absence of external confinement because of quantum effects. The joint team of experimental physicists from Innsbruck and theoretical physicists from Hannover report on their findings in the journal Physical Review X.

“Our Quantum droplets are in the gas phase but they still drop like a rock,” explains experimental physicist Francesca Ferlaino when talking about the...

Im Focus: MADMAX: Max Planck Institute for Physics takes up axion research

The Max Planck Institute for Physics (MPP) is opening up a new research field. A workshop from November 21 - 22, 2016 will mark the start of activities for an innovative axion experiment. Axions are still only purely hypothetical particles. Their detection could solve two fundamental problems in particle physics: What dark matter consists of and why it has not yet been possible to directly observe a CP violation for the strong interaction.

The “MADMAX” project is the MPP’s commitment to axion research. Axions are so far only a theoretical prediction and are difficult to detect: on the one hand,...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

ICTM Conference 2017: Production technology for turbomachine manufacturing of the future

16.11.2016 | Event News

Innovation Day Laser Technology – Laser Additive Manufacturing

01.11.2016 | Event News

#IC2S2: When Social Science meets Computer Science - GESIS will host the IC2S2 conference 2017

14.10.2016 | Event News

 
Latest News

NTU scientists build new ultrasound device using 3-D printing technology

07.12.2016 | Health and Medicine

The balancing act: An enzyme that links endocytosis to membrane recycling

07.12.2016 | Life Sciences

How to turn white fat brown

07.12.2016 | Health and Medicine

VideoLinks
B2B-VideoLinks
More VideoLinks >>>