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Science & Tech.
Pradeep Kumar

25/08/21 11:20 AM IST

Crape materials to be used for the repair of aero-engine

In news

Indigenously developed powders from unused scrape materials to be used for the repair of aero-engine components made of Ni-based super alloy.

Details
  • Indian Scientists have for the first time repaired aero-engine components through emerging additive manufacturing or 3D printing technique called Directed Energy Deposition process that can significantly reduce repair costs and overhaul time.
  • They indigenously made powders suitable for the additive manufacturing process called the Directed Energy Deposition process.
  • Ni-based superalloys are widely used in aero-engine components. 
  • Despite having exceptional properties, they are prone to damage due to extreme operational conditions.
  • Manufacturing defects during the casting or machining process are another major cause of rejection, and tons of such unused components are scrapped due to minor defects.
Technology
  • The ARCI team developed a technology to refurbish pinion housing assembly (critical component in helicopters used for power transmission to the main fan) by machining out the damaged layer and rebuilding it using laser cladding process followed by final machining.
  • Laser cladding and Laser-DED (both processes) are the same.
  • In general, for two-dimensional deposition (surface coating), the term laser cladding is used, and for the manufacture of three-dimensional parts, the term laser-DED is used.
  • A post-clad heat treatment method was also designed to minimize microstructural inhomogeneity and ensure minimal substrate properties variation.
  • These laser-clad repaired prototypes were found to be free from distortion and exhibited excellent performance.
  • The team has also developed repair and refurbishment technologies for other industrial sectors, such as refurbishing diesel engine cylinder heads made of grey cast iron and refurbishing shafts used in the refinery. 
Source: PIB

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