Inconel Blisk Repair Technology Navy SBIR FY2008.1 Sol No.: Navy SBIR FY2008.1 Topic No.: N08-034 Topic Title: Inconel Blisk Repair Technology Proposal No.: N081-034-1181 Firm: POM Group, Inc. 2350 Pontiac Road Auburn Hills, Michigan 48326 Contact: Joohyun Choi Phone: (248) 409-7900 Web Site: www.pomgroup.com Abstract: Advanced aero engines use integrally bladed rotor (IBR)/blisks in the compressor. To maintain affordability, the need for weld repairs of either partial or full blades is warranted to avoid expensive IBR/blisk replacements resulting from foreign object damage (FOD) to the airfoils. Adequate repair technology for blisks due to FOD does not exist, and repaired blisks must meet the OEM design properties. Laser-based direct metal deposition (DMD) process has demonstrated that it can fabricate fully functional metal prototype parts, repair industrial tooling, die-casting and forging, and restore wear resistant and corrosion resistant surfaces for turbine blades. The DMD process equipped with proper sensors and numerically controlled devices can help in overcoming those hurdles to fabricate the blades. Not only thermal control to provide uniform heat flow, but spatial control of crystal texture of the blades by feedback control devices is also essential. The goals of proposal are, (1) to conceptualize, evaluate, and determine the feasibility of repair techniques that will restore the airfoils in an IBR/blisk to their original material properties after a FOD event, (2) to demonstrate cost-effectiveness of the proposed technique, (3) to identify hardware and tools needed for the procedure, and (4) evaluate improvements over current repair methodologies. Benefits: POM envisions laser DMD as an enabling technology for the repair of Nickel-based blisks (integrated blades) and clearly provides a better alternative to the present repair technology at astronomical costs. Once the repair technology is developed, the repairs could be easily carried out at the depots or at regulated OEM sites. For instance, with the replacement cost of these blisks close to half a million dollars each, a superior laser DMD repair could potentially save approximately $4-$5M annually. This projection is based on F136 production projections of approximately 200 engines per year. Return