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.