Review Conference 2015

Conference Day 1, February 25, 2015

Session 1 – Introduction

09:00 Introduction
Prof. Fritz Klocke
Fraunhofer Institute for Production Technology IPT, Aachen (D)
Prof. Reinhart Poprawe
Fraunhofer Institute for Laser Technology ILT, Aachen (D)
09:30 The Future of Gas Turbine Design and Its Effect on Production Methods
Dr. Charles Soothill, Alstom Power, Baden (CH)
10:00 Next Generation Aero Engines – Design and Manufacturing Challenges
Dr. Klaus-Peter Rüd, MTU Aero Engines AG, München (D)
10:30 Coffee Break

Session 2 – Future Challenges

11:00 Design and Turbine Architectures
Dr. Mauro Varetti, GE Avio Srl., Turin (IT)
11:30 Hybrid Materials and Intermetallics
Dr. Dan Roth-Fagaraseanu, Rolls-Royce Deutschland Ltd. & Co. KG, Oberursel (D)
12:00 High Performance Ceramics in Turbomachines – Technical Status and Perspectives
Dr. Jens Schmidt, Fraunhofer Institute for Silicate Research ISC, Würzburg (D)
Lunch Break

Session 3 – Manufacturing

14:00 3D-Master – Consistent Process Integration from Design to Shopfloor
Rainer Ludorf, Alstom AG, Baden (CH)
14:30 Advanced Manufacturing Technologies & Effective Industrialization – Key Success Factors for Next Generation Gas Turbines
Dr. Thomas Neuenhahn, Siemens AG, Berlin (D)
15:00 Guided Tour – Background
Johannes Witzel, Fraunhofer ILT, Aachen (D)
Daniel Schraknepper, Fraunhofer IPT, Aachen (D)
15:30 Transfer to Fraunhofer Facilities by Shuttle Bus

Session 4 – Live Presentations

16:00 Guided Tour at the Fraunhofer Facilities
Live Presentations at the Fraunhofer Institutes
17:30 End of Guided Tour
Transfer back to Eurogress Conference Center
17:45 - 18:45 Art in Architecture
Network of Knowledge by Annette Sauermann

at Fraunhofer IPT and Fraunhofer ILT

Evening Event

20:00 Gala Dinner
»Coronation Hall«, doors open at 19:30 h
23:30 End of Evening Event
  Program subject to minor changes.

Conference Day 2, February 26, 2015

Session 5 – Laser Technologies

09:00 Increase of Productivity by Adaptive Selective Laser Melting
Anders Such, Fraunhofer Institute for Laser Technology ILT, Aachen (D)
09:30 Additive Manufacturing at GE – Challenges and Opportunities
Dr. James Sears , GE Global Research, Niskayuna (US)
10:00 Laser Material Deposition at MAN Diesel & Turbo SE
Christoph Korbmacher, MAN Diesel & Turbo SE, Oberhausen (D)
10:30 Coffee Break

Session 6 – Machining Technologies

11:00 Finish Machining of Complex Blade Geometries
Daniel Schraknepper | Alexander Schäfer,
Fraunhofer Institute for Production Technology IPT, Aachen (D)
11:30 Slot Machining – Process Options and Opportunities
Dr. Gregor Kappmeyer, Rolls-Royce Deutschland Ltd. & Co. KG, Oberursel (D)
12:00 Electrochemical Machining of Turbomachinery Components
Richard Keller, EMAG ECM GmbH, Gaildorf (D)
12:30 Lunch Break

Session 7 – Automation

14:00 Challenges for the Production Ramp-up of Geared Turbofan Engines
Thomas Dautl, MTU Aero Engines AG, München (D)
14:30 Intelligent High Performance Manufacturing
Fuat Atabey, Pratt & Whitney, Montreal, Québec (CA)
15:00 Demands on Production Systems for Turbomachinery Components
Dr. Claus Eppler, CHIRON-WERKE GmbH & Co. KG., Tuttlingen (D)
15:30 Challenges and New Developments in Adaptive Machining
Dr. Claus Bremer, BCT GmbH, Dortmund (D)

Session 8 – Closing

16:00 Industrie 4.0 – A new Dimension of Collaborations
Prof. Günther Schuh, RWTH Aachen University, Aachen (D)
16:30 End of Sessions
  Program subject to minor changes.

Industrial Exhibition

During the accompanying industrial exhibition in the foyer of the conference center various suppliers will present new products and latest trends. Benefit from the exchange of information and know-how at the industrial exhibition as a perfect addition to the ICTM conference. Discuss innovative solutions to your specific problems one-to-one with well-known companies.

  ALZMETALL  Werkzeugmaschinenfabrik und Gießerei Friedrich GmbH & Co. KG
Harald-Friedrich-Str. 2-8
83352 Altenmarkt/Alz, Germany
  C.F.K. CNC-Fertigungstechnik Kriftel GmbH
Gutenbergstr. 8
65830 Kriftel/Taunus, Germany
  EOS GmbH  Electro Optical Systems
Robert-Stirling-Ring 1
82152 Krailling/Munich, Germany
33 Avenue du Maine
75755 Paris, France
  GF Machining Solutions GmbH
Steinbeisstrasse 22-24
73614 Schorndorf, Germany
  Maschinenfabrik Berthold Hermle AG
Industriestraße 8-12
78559 Gosheim, Germany
  IXUN Lasertechnik GmbH
Steinbachstr.  15
52074 Aachen, Germany
  KUKA Industries
Reis GmbH & Co. KG Maschinenfabrik - Geschäftsbereich Reis Lasertec

St. Jobser Straße 53
52146 Würselen, Germany
  Laserline GmbH
Fraunhofer Straße
56218 Mülheim-Kärlich, Germany
  OPEN MIND Technologies AG
Argelsrieder Feld 5
82234 Wessling, Germany
  Renishaw GmbH
Karl-Benz-Str. 12
72124 Pliezhausen, Germany
Industry Sector
Drive Technologies Division
Motion Control Systems
Frauenauracher Str. 80
91056 Erlangen, Germany
  Steinbichler Optotechnik GmbH
Georg-Wiesböck-Ring 12
83115 Neubeuern, Germany
  Third Wave Systems
6475 City West Parkway
Minneapolis, MN 55344, USA

On the first conference day you have the possibility to visit the facilities of Fraunhofer ILT and Fraunhofer IPT. Both Fraunhofer's have gained a huge expertise in manufacturing and repair processes in turbomachinery. In Live Presentations both institutes will demonstrate their latest technology developments on the integration of laser and machining technology as well as measurement technology and CAx into a continuous process chain for turbine components. Use the opportunity to exchange information with our team of experts on-site.


Additive Manufacturing Chain for Tandem Vane Cluster

The demonstration illustrates the manufacturing of a gas turbine tandem vane cluster by selective laser melting and adaptive finishing by milling, as well as relevant CAxtechnologies. Moreover, a method for combined evaluation of design and manufacturing perspective is presented.

  • Combined Evaluation of Design and Manufacturing Perspective
  • Productivity Increase by Using Adaptive SLM Process Strategy
  • Adaptive Milling of Guide Vane Cluster
  • CAx-Technologies for Process Chains


Manufacturing and Repair of Multi-Blir

The demonstration illustrates an integrative process chain for the manufacturing and tip repair of a Multi-BliR. All relevant process steps are presented: New CAx-modules for planning of the machining operations, milling strategies like plunge milling and repair by Laser Metal Deposition. As part of this process chain a new clamping concept for stabilization of thin-walled workpieces like blades during reshaping is demonstrated.

  • CAM-Modules for Advanced Machining
  • Design of Rough Milling Strategies for a Multi-BliR Geometry
  • Technology Processor for Laser Metal Deposition: Process Diagrams
  • Clamping Technology for Thin Walled Workpieces



Comparison of Slotting Technologies

The three life presentations show different technologies for slotting of difficult to cut materials. Milling, Water Jet Cutting and Electrochemical Machining are compared concerning technological and economical aspects.

  • Milling Strategies for Manufacturing of Nickel-based BLISKs
  • Test Bench Five-Axis Water Jet Cutting
  • Analysis on Surface Formation by Electrochemical Machining (ECM)



Further Live Presentations


Fraunhofer Institute for Laser Technology ILT

  • Process Simulation for Powder-based Laser Metal Deposition (LMD)
  • LMD of Steam Turbine Blades by using LMD/CAM Software
  • High Speed Laser Material Deposition
  • Laser Metal Deposition of Intermetallic Alloys
  • Certification of Powder Nozzles for LMD
  • Powder Feeding Nozzles for Laser Metal Deposition
  • SLM of Nickel-based Superalloys Susceptible to Cracking
  • High Power Selective Laser Melting and Resulting Material Properties
  • On-Line Process Monitoring for Selective Laser Melting
  • Remote Laser Drilling
  • Ultrashort Pulse Laser Ablation of Ti6246
  • Machine Tool for Laser Polishing and Examples of Laser Polished Parts
  • Laser Cutting and Joining of Fiber Reinforced Plastics
  • Laser Beam Welding in Repair and Maintenance of Turbo Engines

Fraunhofer Institute for Production Technology IPT

  • Machine Integrated Grinding of Single Blades
  • Robot-based Automation and Integrated Metrology
  • Key Value Based Milling Process Design
  • Grinding of Geometry Adaptive Milling Tools
  • Multi-Tools for Simultaneous Three-Axis Turning
  • Additive Manufacturing of a Compressor Blade of Inconel 718 Solid Wire
  • Competing Process Chains for Blisk Manufacturing
  • Rapid Calibration of Five-Axis Machine Tool
  • Optical Coherent Tomography Measurement of Sharp Edges and Cooling
  • Holes in Turbine Blades
  • Risk Management in Turbomachinery Manufacturing
  • Technology Management

Laboratory for Machine Tools and Production Engineering WZL

  • Modelling of Machining Processes
  • Force Control in Milling
  • Model-based Prediction of the Temperature Field in the Cutting Zone in
  • Broaching
  • Sensor Concept for Chip Transport Monitoring of Gun Drilling Processes
  • High-Speed Wire EDM Slotting of Fir-Tree Geometries
  • Cryogenic Cooling in Cutting Technology