Heuchelheim bei Frankenthal, Germany
Heuchelheim bei Frankenthal, Germany

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Grant
Agency: European Commission | Branch: FP7 | Program: CP-FP | Phase: AAT.2008.4.1.5. | Award Amount: 4.33M | Year: 2009

In the project ADMAP-GAS new Unconventional Advanced Manufacturing Processes for Gas-Engine Turbine Components will be developed in order to substitute the critical conventional broaching process for fir tree profiles between rotating blades and disks. Therefore the two manufacturing technolgies High Speed Wire-EDM Broaching and Abrasive Water Jet Broaching W - will be developed, optimised and evaluated highlighting their individual performance and effectiveness for the machining task. High material removal rates and highest surface finishing will be achieved resulting in an equal or even better workpiece performance. By using these two unconventional manufacturing technologies with their inherent advantages a much higher technological and time based flexibility in production of fir tree profiles can be achieved. Failure risks and machining costs will be drastically decreased due to faster and more efficient machining in combination with a higher degree of automation. Tool wear and time consuming tool renewal can be avoided. Machine tool footprints (in comparison to conventional horizontal broaching centers) or machine heights and fundaments (vertical centers) will be drastically reduced. Energy consumption will be reduced and environment will be preserved. ADMAP-GAS addresses the relevance to the call by the development of techniques for increased flexible tooling for the manufacture of gas turbine components. The W technologies will also enable the application of innovative and light weight design concepts (more complex shapes, tighter tolerances, etc.) for the turbine components that were not possible due to the technical limitations of the broaching process. This will additionally result in reduced production costs across the whole production cycles. Production waste and consumables will be minimised. A high degree of automation and faster machining times will result in a highly effective machining process with virtually no failure risk.


Wilden J.,TU Berlin | Jahn S.,TU Berlin | Milahin N.,TU Berlin | Luhn T.,TU Berlin | And 4 more authors.
Stahl und Eisen | Year: 2010

Complex technical products typically consist of more than one component. Regarding the design of these assemblies, entirely different materials can be used. To manufacture products, which are appropriate to the requirements and loads as well as economically producible, the uses of different materials are needed. The increasing diversity of modern, innovative materials and their continuously increasing strength also lead to more stringent requirements on the joining processes. An economic and energy-efficient solution for these technological challenges can be realized by using innovative brazing processes in combination with new filler materials.


Wilden J.,TU Berlin | Jahn S.,TU Berlin | Melahin N.,TU Berlin | Rehfeldt L.,TU Berlin | And 4 more authors.
Welding and Cutting | Year: 2010

Compared with welding technology, the utilisation of brazing processes for joining reduces the process temperatures and makes it possible to execute demanding mixed joints and to join galvanised steels with minimal damage to the zinc coat. The latest developments of brazing materials are aimed at lowering the melting temperatures and at raising the strengths in order to extend the application possibilities even further. In this respect, not only iron-based alloys but also systems on a copper or zinc basis are subject to constant refinement. The strengths which can already be achieved today extend up to approx. 900 MPa (CuAl8Mn13Ni2Fe2) with copper-based alloys and 410 MPa (AnAl7.5Cu2.5 + 180 ppm Mg) with zinc alloys. In addition to saving energy due to the reduced process temperatures during joining and to the possibility of manufacturing hybrid structures, there are advantages with regard to the repair and recycling of components. Since the filler material can be remelted completely independently of the base material, repairs are easier and the components can also be separated for recycling. When considering the entire product life cycle, this leads to a higher energy efficiency and to the conservation of natural raw materials and resources. Due to the rising energy and material costs and to the cost pressure association with this, the companies are slowly but surely paying greater attention to this aspect in addition to feasibility and productivity. Moreover, cost advantages result from the consideration and modification of whole fabrication chains. Lowmelting filler materials permit, for example, the joining of galvanised semi-finished products without damaging the zinc coat. Since large quantities of semi-finished products can be galvanised at more favourable cost than finished structures, the joining of galvanised semi-finished products is, all in all, more favourable than the galvanisation of welded steel structures.


Klocke F.,RWTH Aachen | Welling D.,RWTH Aachen | Klink A.,RWTH Aachen | Veselovac D.,RWTH Aachen | And 2 more authors.
Procedia CIRP | Year: 2014

This paper deals with a technological evaluation of wire electrode material and machining technologies for the production of fir tree slots by Wire-EDM to compete with the conventional broaching process. Meeting the high requirements on surface integrity and precision, new electrodes in combination with machining technologies have been developed in order to increase the productivity of this machining process. In particular three wire electrodes including a standard brass wire, a coated high-speed-cutting wire and a Ni-coated wire for zero contamination of Cu and Zn in combination with standard and specifically developed machining technologies for cutting Inconel 718 are presented. Evaluation criteria for the comparison are the demanding requirements on fir trees in turbine engine production like precision, surface roughness, minimization of white layer formation and contamination. Finally, an energy consumption analysis of the electrode/machining technology combination is shown. The analyzed processes show that Wire-EDM is a capable process for the fir tree slot production. © 2014 Published by Elsevier B.V.


Patent
Berkenhoff GmbH | Date: 2011-03-28

The invention relates to a wire electrode for spark-erosion cutting. The wire electrode comprises a core made of more than 50% by weight pure crystalline aluminum and/or one or more crystalline aluminum alloys, and comprises a coating layer encompassing the core and comprising copper, zinc, and/or a copper-zinc alloy. The proportion of the surface area of the core relative to the total cross-sectional area of the wire electrode is in the range from 60% to 95% along the entire length of the wire electrode.

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