CORDIS provides links to public deliverables and publications of HORIZON projects.
Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .
Exploitable results
Key results achieved during the project work are:
- improvement of the optical scanning system;
- automation of the scanning process using macro functionality;
- implementation of adaptive technologies into the laser welding process;
- improvement of the milling process by adding adaptive technologies;
- set up of data management system able to store all relevant data and providing the data backbone for the connection of all process steps.
Scanning small filigree parts with shiny surfaces is a problem for optical scanning systems. In case of aero engine parts it is often not allowed to spray the parts to get a matted surface. In Arosatec the scanning methods could be improved so that the laser power can now be adjusted to the surface properties, automatically. With this good scanning results could be achieved even under difficult conditions.
In case of the repair of aero engine parts a complete series of parts has to be processed. To automate the scanning process macro functionalities have been integrated into the scanning system. So the set up procedure is required only once for a series of parts. After the set up the system is able to run in an automatic mode. Here not only the scanning is realised furthermore the necessary calculation of the specific dimensions etc. are carried out.
One requirement for the laser cladding application is to generate the geometry of the part 'near net shape'. This means that the MRO is expecting a very precise shape of the cladded part. There are two reasons for this. First the powder is extremely expensive, so that it is economic to uses as less as possible. The second reason is that material which had been added has to be removed down to the parent geometry. So a huge amount of weld implies a long and expensive milling process. All these requirements could be met by adding adaptive technologies to the welding process. So the cladding can now be adjusted to the individual shape and the process itself can be influenced by various parameters.
The adaptive technologies have also been integrated into the milling process. Here the requirements concerning the exactness of the milled shape are challenging. So, it is not possible to use one standard NC programme for the repair of a series of run engine parts. Each part has to be measured first, so that the NC programmes used for tip or edge repair can be adjusted to each individual repair part. With this approach the requirements of the industrial partners could be met. All the improvements mentioned above are supported by the data management system. The scanning data measured during the incoming inspection are available for generating an adapted path for laser cladding. So, all process steps have been equipped with an interface allowing to get data from the database and to store date there. For storing different types of data XML-technologies have been chosen.
Futhermore, the data management systems allows to monitor the status of each individual repair part. The path through the process chain can be tracked by the user. It is possible to connect the Arosatec data management system to the bespoke systems used at the MRO shops.
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