Develop MAR-M-247 Repair with Direct Energy Deposition (REP-MAR)

Purpose and goal:

The objective of this project is to conduct experiments in order to evaluate if Direct Energy Deposition (DED) followed by Hot Isostatic Pressing (HIP) can be used as a repair process for cast defect on the non-weldable MAR-M-247 alloy. The goal is to improve operational efficiencies and sustainability in the aerospace sector by evaluating this new repair process. There is today no available method to repair these alloys and foundries are therefore often forced to scrap the components.

Expected results and effects:

A successful project would lead to significant energy savings by reducing the need for remelting and lowering operational costs through minimized material waste and processing time. This supports both environmental objectives and competitiveness by promoting a more resource-efficient manufacturing process. Furthermore, this project offers significant potential for Swedish SMEs to enhance their efficiency in fabricating high-performance MAR-M-247 parts, thereby strengthening their position in the national aviation supply chain.

Approach and implementation:

The project involves collecting parts with surface defects, which will be repaired using DED. Various process parameters for both DED and HIP will be evaluated to identify the optimal process window. Additionally, the components will undergo different heat treatments to prevent formation of new defects (cracks).

The effectiveness of the repair process will be assessed through detailed microstructural analysis. The project will include regular updates, dissemination of findings, and a final report.