The blisk is a key component of the aero-engine components. During use, the blade tips are prone to wear, and both ends of the blade roots are prone to cracks and failure, leading to scrapping. Laser additive manufacturing technology can be used to control deformation well and achieve the traditional surfacing method. Unachievable restoration precision. The use of laser repair additive manufacturing technology can realize the direct molding of the entire blisk in a short time, which can save costs and improve production efficiency to a large extent.

Background of The Project
Currently, the blisk is manufactured by forging. The forging cost is high and the cycle is long. The forged blisk also has some metallurgical defects. Laser direct forming of aero-engine blisks can reduce costs and speed up cycle times. The integral blisk of aero-engines is prone to defects such as tip wear and cracks during use. In most cases, they are simply scrapped because they cannot be repaired. The cost of directly replacing the entire blisk of an aeroengine is very expensive, and the cost of a new product is generally not less than one million. There have been successful cases of laser remanufacturing and repair of integral leaf disks abroad. Due to foreign technical barriers, there are few successful applications of laser remanufacturing technology for integral blades in my country. Therefore, the development of laser remanufacturing technology for whole blisks is an urgent technical issue to be solved.

Project Sample
The overall blisk base material and laser cladding material are both TC17 and GH4169G. The laser cladding metallographic inspection meets the inspection requirements. The layer thickness is appropriate, the sides are well-formed, there are no metallurgical defects, and the structure is uniform.

Mechanical properties sample molding effect:

After the mechanical properties sample passes the test, single component cladding and sample cladding repair will be carried out. Defects are artificially created and repaired through laser fusion. In order to ensure trimming after cladding, a certain thickness needs to be ensured, and the scanning path needs to be designed according to the shape of the blade.
Through the single component cladding test, the feasibility of cladding, the stability of the process, and the cladding effect of the single component blade, including deformation and whether there are defects, were confirmed. The machining allowance and deformation amount were confirmed through modification after cladding. etc.

The inspection after cladding showed no defects, and the final result met the project acceptance standards.

The entire blisk laser additive manufacturing repair project completed the following technical contents and all passed the assessment test

1. Study laser cladding performance.
2. Conduct basic process research and development.
3. Design and develop tooling and equipment suitable for laser additive manufacturing of whole blisk
4. Develop additive manufacturing equipment and repair process technology suitable for integral blisks.
5. Carry out single component sample repair test.
6. Conduct overall blisk repair test.
7. Conduct mechanical performance testing, post-repair testing of single components and entire components.