Page 25 - AAA MARCH - APRIL 2019 Online Magazine

selective laser melting, or SLM for short. MTU Aero Engines used
AM processes for production of borescope bosses since 2013, for
the PurePower PW1100G-JM geared turbofan engine.

MTU is currently working on a seal carrier manufactured using
additive processes, where the inner ring with an integral honeycomb
structure will be installed in the high-pressure compressor. This will
improve clearance control, and hence to increase efficiency. AM
processes will also be use to produce additional components, such
as bearing housings, brackets and struts in the future.

Compelling advantages
Lufthansa Technik also established its own AM center at the begin-
ning of 2018, where a joint team of Lufthansa Technik experts and
AM specialists from industry partners and research institutions
develop strategies to support the introduction of this technology.
For Lufthansa Technik as an MRO provider, a key focus is obviously cal printers in three locations (including one in
set on the development of repair processes. Dr. Aenne Koester, who Hamburg, Germany). Such tests are expected
heads the AM Center, explains: “While almost all product divisions to set process tolerance standards to ensure
of Lufthansa Technik have gathered considerable experience in this that AM products produced at different loca-
area, the new AM Center will serve as a collaborative hub where the tions, deliver the desired performance goals
experience and skills that Lufthansa Technik has gained in relation with the required level of certainty.
to additive manufacturing can be bundled and further expanded.
Its aim is to increase the degree of maturity of the technologies Lufthansa Technik has already made significant
and to develop products that are suitable for production.” progress with its focus on nickel-based alloys,
highly-stressed engine components which are
A key challenge in the aviation industry remains the creation of of special interest for the AM development
standards for AM processes for the highly-regulated world of team. The MRO provider is one of very few
commercial aircraft operations and its following transfer to the companies capable of performing what is called
MRO sector. There is also the challenge that OEMs and MROs a powder bed fusion hybrid batch repair – an
will look to guard their businesses in this arena. Towards this end, AM process in which a damaged part such as
Lufthansa Technik has an ongoing cooperation with Oerlikon, a blade is repaired by replacing lost material.
aimed at enhancing the understanding of process repeatability, It goes without saying that such a process
which the MRO leader calls as, ‘a key element of industrialization requires extremely tight tolerances, not just
and certification’. To better understand all parameters influencing in work holding. Additive manufacturing offers
the performance of a part manufactured using AM processes, many opportunities, not only for the production
representative component geometries will be printed on identi- of new and spare parts but also in the areas of
fixture construction and repair development.

ASIAN AIRLINES & AEROSPACE March/April 2019 | 25