Turbine blades made from nickel-based superalloys are highly stressed components whose repair places exceptional demands on the process. Even the smallest defects — such as microcracks in the repaired areas — can significantly reduce blade service life. In the project "Sensor-supported qualification of regenerated turbine blades" (SAMrep), the Additive Manufacturing – Metals group at LZH is working to advance the laser- and powder-based additive manufacturing process known as Directed Energy Deposition (DED) for use in such repairs. In this process, metal powder is applied layer by layer to the damaged component and fused with the base material by a laser. 

Sensor technology for greater process stability 

To detect and prevent defects during the DED process, the researchers are employing advanced sensor technology and multispectral process monitoring. This approach is intended to enable non-destructive inspection directly during the deposition process. 

About SAMrep 

The SAMrep project is funded by the Investment and Promotion Bank of Lower Saxony (NBank) using resources from the European Social Fund Plus and the European Regional Development Fund. Project partners are 4D Photonics GmbH and Laser Zentrum Hannover e.V.