Master thesis

Evaluation of additive manufacturing processes for the repair of turbomachinery components from nickel-based

super alloys

Motivation Direct Metal Deposition (DMD) is a further development of laser deposition welding to create 3 dimensional struc-

tures. During this additive manufacturing process metal powder particles are blown and melted into a melt pool

which is created by the laser such that layer by layer are generated to obtain a volumetric structure. In the indus-

try this manufacturing process is used for example for the repair of turbine blades.

The application of DMD is especially economic for materials that are difficult to machine. This is the case for ex-

ample for nickel-based super alloys which are used mainly for high temperature applications such as tur-

bomachinery components. To work with such materials at the 5 axis laser deposition center of the IWF it is re-

quired to find appropriate process parameters to ensure a good part quality. Additionally it is required to further

develop the deposition strategy to be able to repair turbomachinery components. This parameter optimization and

development of a deposition strategy for repair processes is to be performed during the master thesis.

DMD-processing head DMD process principle

Task description - literature research - design of experiments - sample production - experiment evaluation - documentation and presentation of the results

Requirements

- Interest in experimental work - Independent working style

Duration / begin - Duration: 6 months - Begin: flexible

Contact Fabian Soffel, ETH Zürich, 044 633 08 49 soffel@iwf.mavt.ethz.ch Daniel Eisenbarth, inspire AG 044 633 79 56 eisenbarth@inspire.ethz.ch