Large-scale turbine blade demonstrates potential of Wire-laser Additive Manufacturing

News
June 30, 2019

June 30, 2019

Large-scale turbine blade demonstrates potential of Wire-laser Additive Manufacturing

Detail of the large-scale stainless steel turbine blade produced by ADDere using WLAM (Courtesy ADDere)

 

ADDere, the Additive Manufacturing division of Midwest Engineered Systems Inc., headquartered in Waukesha, Wisconsin, USA, has used its Wire-laser Additive Manufacturing (WLAM) process to build a large-scale stainless steel turbine blade, produced by depositing 1,800 layers or 61 kg (135 lb) of material in just thirty hours. The turbine blade measures 1800 mm (5 ft 11 in) tall and 500 mm (20 in) wide, with 5 mm side walls and a hollow interior.

“While the complex shape was made in record time, the part is pretty spectacular in my opinion,” stated Scott Woida, ADDere President. ”The real story is being able to build such a large part on our system and stay so close to tolerances throughout the build is the most exciting aspect for us.“

ADDere’s proprietary closed-loop feedback system is said to have been instrumental in not only monitoring and maintaining the deposition quality in near real time, but also overseeing consistent dimensional accuracy during the application of the stainless steel material over the course of the build, while the ADDere WALS control software reportedly took into account the myriad of issues regarding the heating, cooling and flow of metal to mitigate internal stresses that could develop at the metallurgical level.

 

Large-scale turbine blade demonstrates potential of Wire-laser Additive Manufacturing

The turbine blade measures 1800 mm (5ft 11in) tall and 500 mm (20 in) wide, with 5 mm side walls and a hollow interior (Courtesy ADDere)

 

“It’s a very complex process. Being able to hold dimension across thirty hours of metal heating and cooling, expansion and contraction, is a testament to how much knowledge has gone into the development of the software and control systems of the ADDere systems,” commented Pete Gratschmayr, VP Sales & Marketing. “We’re excited to take on large challenges to prove the system further.”

ADDere’s WLAM system is specially developed for the AM of large scale, near-net shape parts in a variety of metals including titanium, Inconel, stainless steel and other superalloys, as well as most ferrous-based metals. The standard ADDere system features a build area of 2 m x 1 m x 1 m  (79 in x 39 in x 39 in).

Aside from the AM of complete parts, the ADDere process can also be used to deposit new metal forms on components made through other processes, like casting, machining or forging. The firm’s material deposition process allows for the ability to not only make production runs with small part variations more economical but also allow for the repair of large metal components.

News
June 30, 2019

About Metal Additive Manufacturing magazine

Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

In addition to providing extensive industry news coverage, Metal AM magazine is known for exclusive, in-depth articles and technical reports.

Our focus is the entire metal AM process from design to application.

Each issue is available as an easy-to-navigate digital edition and a high-quality print publication.

In the latest issue of Metal AM magazine

Download PDF
 

Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • Fly-by-wire: How Additive Manufacturing took to the skies with Norsk Titanium
  • Dynamic beam shaping: Unlocking productivity for cost-effective Laser Beam Powder Bed Fusion
  • Enabling the fusion energy revolution: Mastering tungsten with PBF-EB Additive Manufacturing
  • Patents and Additive Manufacturing: What insights can mining PBF-EB data reveal about the industry and the technology?
  • Additive Manufacturing for Semiconductor Capital Equipment: Unlocking critical supply chains
  • Can Additive Manufacturing lower the carbon footprint of parts for the energy and maritime industries?
  • Inspect Additive Manufacturing, stop monitoring: Phase3D’s unit-based, in-process inspection solution for powder bed AM

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

Looking for AM machines, metal powders or part manufacturing services?

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

  • AM machines
  • Process monitoring & calibration
  • Heat treatment & sintering
  • HIP systems & services
  • Pre- & post-processing technology
  • Powders, powder production and analysis
  • Part manufacturers
  • Consulting, training & market data
View online

Discover our magazine archive…

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

  • Reports on visits to leading metal AM part manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

Browse the archive

Share via
Copy link
Powered by Social Snap