Inconel Blisk Repair by Laser Deposition Navy SBIR FY2008.1 Sol No.: Navy SBIR FY2008.1 Topic No.: N08-034 Topic Title: Inconel Blisk Repair by Laser Deposition Proposal No.: N081-034-0332 Firm: Optomec Design Company 3911 Singer NE Albuquerque, New Mexico 87109 Contact: Richard Grylls Phone: (419) 230-3246 Web Site: www.optomec.com Abstract: Blisks are important in the design of modern aircraft engines. They offer attractive performance benefits, but due to their expense they require robust repair schemes, in order to avoid costly replacement during overhaul. The Laser Engineered Net Shaping (LENS) process has demonstrated repair of blisks without compromising mechanical integrity. LENS is an additive manufacturing technique, where the original material, in this case Inconel, is deposited in the repair area to achieve a full metallurgical bond, with properties often approaching those of the original material. In this work we will develop a repair for an Inconel blisk airfoil that has suffered Foreign Object Damage. In Phase I we will investigate methods to refine the grain size of LENS-deposited Inconel, and investigate localized heat-treatment. We will also look at methods to understand and control the deposition and heat-treatment processes. In the Phase I option, we will refine the processes, model them, and test the properties of the materials. In Phase II, we will develop and demonstrate the entire repair process, and show whether proceeding to qualification would result in a return on investment for the Navy. Benefits: The anticipated benefits of this technology are to improve the readiness of the T700, F119, F135 and F136 engines, by providing a significant cost reduction over purchasing replacement blisks, and improving readiness by providing a means to return the blisks to service. Blisks are increasingly being used in commercial jet engines, where the same cost and readiness issues exist. The techniques developed here can also be applied to Inconel fan and compressor blades, and to Inconel components in other industries, such as the petrochemical industry. Return