Maintenance, Repair and Overhaul

Maintenance, repair and overhaul refers to the classic maintenance and repair business used to overhaul components, systems and machines. This is typically carried out using static repair process chains in which the same value-added steps are carried out continuously. After repair or maintenance, the systems and machines continue to be operated with identical properties.

The use of future technologies such as digital solutions or additive manufacturing processes can lead to product and process innovations that allow operating intervals to be extended. As part of the Werner-von-Siemens Center, components, systems and machines will no longer be repaired in the traditional way, but will be equipped with better properties using new technologies during the repair process: Upgrade instead of repair. Improved properties in turn lead to greater efficiency and lower emissions.

To this end, new dynamic process chains are being developed in which the value creation steps are specified through digitalization. Each component is to pass through an individual repair chain. This development will be demonstrated using the example of gas turbine blades, which can be operated at higher temperatures or longer operating intervals after repair. At Fraunhofer IPK, we are developing adaptive, additive technologies for blade repair and digitizing the entire repair process by integrating digital twins, from the recording of findings and the self-control of the coating process to machine data acquisition and the introduction of assistance systems for the worker.

Relevant research questions

• How can we not only repair components during the service process using adaptive and additive manufacturing processes, but also equip them with improved properties?
• Can digitalization and automation make repair process chains more dynamic and faster?
• How can activities be supported and improved by artificial intelligence?

Target group

• Large companies in the energy sector
• Users of additive manufacturing and complex manufacturing process chains
• Companies with digitally supported production