The Integrated Manufacturing Technologies Institute of the National Research Council of Canada (NRC-IMTI) has been developing an advanced laser consolidation (LC) process that produces functional net-shape complex components layer by layer directly from a CAD file without moulds or dies. This platform technology has many potential applications in aerospace, automotive, power generation, medical device, defense and other manufacturing sectors.

This work was completed in collaboration between NRC-IMTI and GE Global Research to explore the feasibility of using the innovative LC process to build functional net-shape Ti-6Al-4V airfoils with embedded cooling channels. The results demonstrated that the LC Ti-6Al-4V airfoils are metallurgically sound without any cracks or porosity. The dimensions of LC airfoils accurately represent the design features described in a CAD model. This work demonstrates that the laser consolidation process provides an excellent opportunity to materialize the innovative designs, such as airfoils with embedded cooling channels, which may be very difficult or impossible to manufacture using other conventional methods.

1.
Keicher
,
D.M.
,
Miller
,
W.D.
,
Smugeresky
J.E.
&
Romero
,
J.A.
(
1998
)
Laser Engineering Net Shaping (LENS™): Beyond Rapid Prototyping to Direct Fabrication
, in
Proceedings of the 1998 TMS Annual Meeting
,
San Antonio, USA
,
369
377
.
2.
Abbott
,
D.H.
&
Arcella
,
F.G.
(
1998
)
Laser Forming Titanium Components
,
Advance Materials and Processes
153
,
29
30
.
3.
Mazumder
,
J.
,
Choi
,
J.
,
Nagarathnam
,
K.
,
Koch
,
J.
&
Hetzner
,
D.
(
1997
)
Direct Metal Deposition of H13 Tool Steel for 3-D Components
,
JOM
49
,
55
60
.
4.
Xue
,
L.
&
Islam
,
M.U.
(
2000
)
Free-Form Laser Consolidation for Producing Metallurgically Sound and Functional Components
,
Journal of Laser applications
12
,
160
165
.
5.
Milewski
,
J.O.
,
Lewis
,
G.K.
,
Thoma
,
D.J.
,
Keel
,
J.I.
,
Nemec
R.B.
&
Reinert
,
R.A.
(
1998
)
Directed Light Fabrication of A Solid Metal Hemisphere Using 5-Axis Powder Deposition
,
Journal of Materials Processing Technology
75
,
165
172
.
6.
Wu
,
X.
&
Mei
,
J.
(
2003
)
Near Net Shape Manufacturing of Components Using Direct Laser Fabrication Technology
,
Journal of Materials Processing Technology
135
,
266
70
.
7.
Xue
,
L.
,
Theriault
,
A.
,
Rubinger
,
B.
,
Parry
D.
,
Ranjbaran
,
F.
and
Doyon
,
M.
(
2003
)
Investigation of Laser Consolidation Process for Manufacturing Structural Components for Advanced Robotic Mechatronics System
, in
Proceedings of ICALEO’ 2003
,
Jacksonville, USA
,
E134
E143
.
8.
Xue
,
L.
,
Chen
,
J.-Y.
&
Theriault
,
A.
(
2002
)
Laser Consolidation of Ti-6Al-4V Alloy for the Manufacturing of Net-Shape Functional Components
, in
Proceedings of ICALEO’ 2002
,
Scottsdale, USA
,
169
178
.
9.
Xue
,
L.
,
Theriault
,
A.
,
Chen
,
J.
,
Islam
,
M.U.
,
Wieczorek
,
A.
&
Draper
,
G.
(
2001
)
Laser Consolidation of CPM-9V Tool Steel for Manufacturing Rotary Cutting Dies
, in
Proceedings of 10th International Symposium on Processing and Fabrication of Advanced Materials
,
Indianapolis, USA
,
361
376
.
10.
Xue
,
L.
,
Purcell
,
C.
,
Theriault
,
A.
&
Islam
,
M.U.
(
2001
)
Laser Consolidation for Manufacturing Complex Ultrasonic Transducer Sensors
, in
Proceedings of ICALEO’2001
,
Jacksonville, USA
,
702
711
.
11.
Xue
,
L.
,
Chen
,
J.-Y.
,
Islam
,
M.U.
,
Pritchard
,
J.
,
Manente
,
D.
&
Rush
,
S.
(
2000
)
Laser Consolidation of Ni-Base IN-738 Superalloy for Repairing Gas Turbine Blades
, in
Proceedings of ICALEO’2000
,
Dearborn, USA
,
D.30
D.39
.
This content is only available via PDF.
You do not currently have access to this content.