GKN Aerospace Taps DED for Geared Turbofan Engine Repairs
GKN Aerospace has secured multi-year repair contracts from Pratt & Whitney for geared turbofan engines, utilizing directed energy deposition (DED) additive manufacturing to restore components.
GKN Aerospace has been awarded a series of multi-year repair contracts by Pratt & Whitney, covering over 20 component types for the geared turbofan (GTF) engine family. These agreements, ranging from 5 to 10 years, will see work distributed across GKN facilities in Sweden, Malaysia, and the United States.
The scope of these contracts is extensive, encompassing engine cases, structures, and rotating parts. A key differentiator from standard maintenance agreements is the integration of directed energy deposition (DED), an additive manufacturing process, for the repair of engine components that are beyond the scope of conventional repair methods.
Specifically, GKN's facility in Trollhättan, Sweden, will employ DED for Exit Guide Vane (EGV) stator repairs. This process precisely deposits new material onto worn areas of components, rebuilding geometry that would typically necessitate discarding the part under older repair techniques. For the GTF program, which faces significant maintenance, repair, and overhaul (MRO) demand, this capability directly impacts turnaround times, costs, and supply chain pressures.
Complementing the Swedish operations, GKN's facility in Johor, Malaysia, will undertake stator and stator assembly component repairs, leveraging the region's growing technical expertise. This site will also expand into advanced composite fan blade repairs. Concurrently, GKN's San Diego facility is enhancing its capabilities with thermal coating applications and advanced ultrasonic shot peening, a surface treatment designed to improve fatigue and wear resistance.
The adoption of DED is significant because it offers a more controlled heat input compared to some traditional methods. This precision allows for the rebuilding of worn features while preserving the metallurgical integrity of the component. Pratt & Whitney has already validated this approach for GTF structural case repairs, reporting substantial process time reductions and estimating significant cost savings over time by salvaging parts that would otherwise be scrapped.
This development highlights the increasing adoption of DED additive manufacturing for critical aerospace MRO. By enabling the repair of components previously deemed irreparable, DED extends component life, reduces scrap, and alleviates pressure on new part production. This aligns with the broader industry trend of leveraging AM for cost reduction, supply chain resilience, and enhanced sustainability in aviation.
Edited by the news editor with AI from the original report — please refer to the original source.