Additive Manufacturing of Crack Sensitive Inconel 738

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Additive Manufacturing (AM) is a disruptive technology that incrementally builds very complex objects layer-by-layer directly from a digital file, objects impossible to produce by conventional machining. Turbomeca Canada is a key company in the field of aerospace, with a very strong expertise in manufacturing, repair and overhaul of helicopter engines. Turbomeca Canada desire to embrace AM to improve their competitiveness and process portfolio to reduce time for delivery, increase design/manufacturing efficiency, adopting new repair procedures and lower production/repair cost of their aerospace parts, which will lead to the ultimate goal of business growth. This proposal will research data and provide Turbomeca Canada with answers regarding the new possibilities in terms of microstructure, segregation phase and content developed during AM of IN738, an alloy considered unweldable. This knowledge is critical to determine if AM can open new manufacturing or repair routes for these high cost aerospace parts. The main objectives are to: (1) determine the window of solidification allowing for AM of IN738, (2) experimentally validate this processing window, including part characterisation and (3) translate this knowledge to simulate an actual IN 738 part re-built. Prof. Brochu's group has developed and validated new methodologies to perform AM of unweldable alloys and thus can provide an answer to successful AM of IN738, which closes this scientific bridge. This initiative is also supported by CRIAQ, to facilitate the establishment of this strategic aerospace-based AM research projects.