With the increasing demands for resource efficiency and emission reduction in aviation, as defined in "Flightpath 2050", new technological challenges are also being placed on the existing manufacturing process chains. Current developments show that future engine generations will use smaller, more complex core engines and higher overall pressure ratios. The resulting challenges for manufacturing are fundamentally both smaller engine components with higher tolerance requirements and the increased use of more heat-resistant materials, such as nickel-based alloys.

Integration of laser powder bed fusion into the manufacturing process chain for engine components

The focus of the collaborative project "AMB2S" are on goals of environmentally friendly, high-performance and efficient aviation. The underlying objectives of the funding programme are achieved by using the Laser Powder Bed Fusion (LPBF) process within the manufacturing process chain for engine components. Here, the high resource efficiency and the high degree of design freedom are especially in the focus. In particular, the near-net shape manufacturing of engine components using LPBF promises a significant increase in efficiency compared to conventional manufacturing process chains. In order for LPBF to be used for the manufacturing of engine components, the innovative technology must be integrated into a manufacturing process chain.

The project objectives at a glance

• Development of a process chain for engine components consisting of additive (LPBF) and conventional manufacturing using the example of BLISK
• Qualification of additively (LPBF) manufactured engine components with regard to the current standards for aviation

In order to achieve these goals, the "AMB2S" research project is mapping a holistic process chain from design, additive manufacturing, heat treatment and finish machining to quality assurance for the manufacture of engine components using the example of a BLISK. For this reason, the consortium of the research project includes companies that have all the necessary competences to map such a manufacturing process chain.

Partners

• Fraunhofer-Institute for Production Technology IPT, Aachen
• RWTH Aachen Chair of Digital Additive Production DAP
• PRÄWEST PRÄZISIONSWERKSTÄTTEN Dr.-Ing. Heinz-Rudolf Jung GmbH & Co. KG, Bremen
• BCT Control and Data Processing Systems GmbH, Dortmund
• Innoclamp GmbH, Aachen
• MMB Maschinen, Montage & Betriebsmitteltechnik GmbH, Velbert
• Oetzbach Stainless Steel GmbH, Velbert
• TPW Test Center GmbH, Neuss

Project Funding

The research project is funded by the German Federal Ministry for Economic Affairs and Climate Action (BMWK).

Project Manager

German Aerospace Center e.V.

Funding Reference

20T1925H