Research means shaping the future!

CMC-3D
Development of an automatic inline measurement and defect detection system for efficient, adaptive finishing of complex CMC turbine components

Increasing the efficiency of aircraft engines requires higher operating temperatures. Ceramic matrix composites (CMC) can withstand the high loads in the engine and thus allow higher operating temperatures than components made of nickel-based alloys.

The mechanical processing of CMC components presents new challenges for manufacturing technology. The workpieces themselves exhibit small defects such as pores and cracks that must be machined or addressed. In addition, microcracks in the surface and local spalling and delamination occur during the machining of oxide and non-oxide CMC materials.

In CMC-3D, the actual geometry of the CMC blank is captured using high-precision 3D scans with white light interferometry (WLI). Based on this data, NC machining can be flexibly and automatically adapted to the actual blank, taking into account any quality defects.

BCT integrates the WLI sensor into a 5-axis machining center and spatially assigns detected defects to the component’s geometry. Adaptation technology is used for optimal milling of CMC components, enabling customised machining tailored to the defects.

3D-REFLEKT

Process control and path planning for the EHLA-3D process for the repair and coating of turbine blades

Extreme high-speed laser cladding (EHLA) enables significantly higher feed rates and thin, dense, fused-metallurgically bonded layers compared to conventional laser cladding (Laser Metal Deposition/LMD), while significantly reducing teh heat input. This makes EHLA ideal for the repair and coating of engine components with the highest quality requirements.

The goals of 3D-REFLEKT are the integration of the EHLA-3D process into a sensor-supported, automated process chain for the repair and coating of turbine blades and an expansion of the material spectrum compared to the state of the art.

BCT leads the consortium and is responsible for the development of a user-friendly software environment for controlling and automating the EHLA 3D process chain, consisting of 3D laser line scanning, EHLA 3D cladding, and 5-axis recontouring.

ISEGRIM

Identifying damage caused by erosion in the fusion generator and regenerating the material using LMD-wire

The service life of plasma wall components plays a key role in the economic success of future fusion reactors. However, damage caused by erosion severely limits service life. Replacing worn components would be extremely time-consuming and costly.

The ISEGRIM consortium, led by BCT, has therefore set itself the goal of developing a cost-effective repair system for the in-situ regeneration of eroded plasma wall components using wire-based laser metal deposition (LMD-w). Such repairs must be performed within a small process window with high temperature gradients and under the specific environmental conditions of fusion reactors.

BCT’s focus is on sensor-based process control and monitoring of the LMD-w process, as well as on the autonomous operation of the repair robot for addressing localized, individual damage. BCT’s innovation lies in the implementation of the tungsten LMD-w process into a practical, automated, industrialized in-situ repair solution to achieve controlled quality results.