Analysis of parameters influencing build accuracy of a SLM printed compressor outlet guide vane

Abstract

The paper describes the manufacture of an outlet guide vane (OGV) of jet engines by the Selective Laser Melting (SLM) process, in view of current challenges for conventional machining approaches such as; high airfoil profile tolerances, limited tooling access and hard to machine materials like nickel-chromium-based super alloys. Within this paper, analysis was conducted to investigate the influence of build parameters on possible distortion during printing that affect the build accuracy. These parameters include the part orientation on the build plate, thickness change to the flanges and the positioning of the support structure of each part. The configurations are 3D printed using the SLM approach. The chosen material is IN625. The printed parts are 3D scanned and the results are compared to the original CAD design. The results confirmed the presence of distortions in printed parts and the effect of parameter changes. Furthermore, it was shown that improvements to the print parameters are necessary to achieve a satisfactory profile tolerance.