Hybrid manufacturing saves material and reduces tool wear
The development of additive processes for machining geometrically complex and delicate structures of any size is one of Fraunhofer IAPT’s specializations. The IKARUS project deals with the additive reinforcement of a forged, thin-walled base structure for the production of a metal leading edge to protect CFRP turbine blades.
In the manufacturing process, Fraunhofer IAPT receives a forged base structure from project partner Leistritz and applies additional material to the slender edge of the metal leading edge using the DED-LB/P process. The exact placement of the material, the correct angle, and the precise delivery of energy require a complex machining strategy and precise process control.
For the demanding material deposition, Fraunhofer IAPT experts work with project partner Access to develop a synchronized eight-axis movement. Based on the institute’s high process competence, the movements were implemented with adapted process and path planning. The approach guarantees reliable deposition of the titanium alloy while simultaneously avoiding any damage to the delicate component.
Fraunhofer IAPT’s expertise in handling delicate large-scale structures enabled the hybrid fabrication of the leading edge, resulting in savings of more than half of the titanium alloy that would be required in purely conventional production.
In addition to material savings, hybrid production also reduces tool wear and post-processing effort.