Pratt & Whitney Introduces New AM Repair Solution for GTF Engines

Pratt & Whitney has introduced a new additive manufacturing (AM) repair solution for critical geared turbofan (GTF) engine components. Developed at the company’s North American Technology Accelerator in Jupiter, Florida, the new technology utilises Directed Energy Deposition (DED), a 3D printing method that enables repair to GTF structural case features.

By streamlining the repair sequence and eliminating multiple steps from the current repair method, the new technique is expected to cut overall repair process time by over 60% and improve turnaround time. The most substantial improvements come from the minimised machine changeovers and reduced heat treat cycles.

Kevin Kirkpatrick, Vice President of Aftermarket Operations at Pratt & Whitney, said that the new additive repair process helps to reduce the company’s “dependency on current material supply constraints” and allows them to “better serve our customers by improving turnaround time, while reducing tooling costs, complexity and set up.”

“Additive technology has the potential to support a range of critical GTF part repairs and we’re actively working to explore additional opportunities for implementation,” Mr Kirkpatrick added.

This new innovation was developed in collaboration with the Connecticut Center for Advanced Technology and the RTX Research Center. Beyond its current application, the technology will also be used in the future to restore components affected by normal engine wear and tear.

Pratt & Whitney is also currently in the process of industrialising the repair method, with plans to scale and deploy its use across the global GTF Maintenance, Repair, and Overhaul (MRO) network. Over the next five years, the company expects to recover $100 million worth of parts through the implementation of additive repairs across its MRO operations.

Photo Credit: Pratt & Whitney