Gas Turbine Blade Failures Repaired Using Laser Metal Additive Remanufacturing

The production of reliable turbo machinery, particularly gas turbine blades, is a major global challenge. This capability serves as a key indicator of a nation's industrial base, technological prowess, and comprehensive strength. Critical components in aircraft engines and gas turbines operate under extreme conditions, including high temperatures, high pressures, and substantial mechanical stresses. Consequently, there is a growing urgency to develop cost-effective and time-efficient repair strategies to enhance engine performance and efficiency. However, many mission-critical parts, especially high-pressure (HP) blades, are prone to severe damage. Moreover, taking equipment offline for blade maintenance and repair is a time-consuming process. It is also highly costly to restore these essential components to full functionality. Since 1996, researchers have focused on applying laser metal deposition (LMD) additive manufacturing technology for high-performance repair and remanufacturing of aerospace engines and industrial gas turbine (IGT) blades. Empirical studies have demonstrated that depositing a high-quality, erosion-resistant protective coating on the leading edge of HP blades effectively extends the service life of turbine blades in both aircraft engines and industrial gas turbines. This study systematically outlines the technical workflow of the proposed methodology and provides a concise perspective on emerging development trends.