Application of Directed Energy Deposition-Based Additive Manufacturing in Repair

Abstract

In the circular economy, products, components, and materials are aimed to be kept at the utility and value all the lifetime. For this purpose, repair and remanufacturing are highly considered as proper techniques to return the value of the product during its life. Directed Energy Deposition (DED) is a very flexible type of additive manufacturing (AM), and among the AM techniques, it is most suitable for repairing and remanufacturing automotive and aerospace components. Its application allows damaged component to be repaired, and material lost in service to be replaced to restore the part to its original shape. In the past, tungsten inert gas welding was used as the main repair method. However, its heat affected zone is larger, and the quality is inferior. In comparison with the conventional welding processes, repair via DED has more advantages, including lower heat input, warpage and distortion, higher cooling rate, lower dilution rate, excellent metallurgical bonding between the deposited layers, high precision, and suitability for full automation. Hence, the proposed repairing method based on DED appears to be a capable method of repairing. Therefore, the focus of this study was to present an overview of the DED process and its role in the repairing of metallic components. The outcomes of this study confirm the significant capability of DED process as a repair and remanufacturing technology.

Thermomechanical modelling for the linear friction welding process of Ni-based superalloy and verification

“…12 LFW process is highly economical in terms of energy cost and energy consumption, as it can effectively improve the manufacturing competitiveness of the industry and avoid negative environmental impact. 15 To date, the foremost application of LFW application is in the manufacture and repair of integrally bladed disks (blisks) shown in Figure 1. [16][17][18] Blisks are critical components of axial-flow compressors of gas turbine engines.…”

Comparative Quality Control of Titanium Alloy Ti–6Al–4V, 17–4 PH Stainless Steel, and Aluminum Alloy 4047 Either Manufactured or Repaired by Laser Engineered Net Shaping (LENS)

“…Regarding maintenance, aircrafts’ mechanical parts such as those placed in the engine or the landing gear, erode over time, losing material and failing to meet their critical dimensional requirements. Some AM processes, such as directed energy deposition (DED) [ 4 , 5 , 6 , 7 ], enable the addition of material to existing parts without harming them. This can greatly reduce maintenance costs without risking flight safety.…”

The Interface Microstructures and Mechanical Properties of Laser Additive Repaired Inconel 625 Alloy

“…By using the damaged or mis-machined components as substrates, the geometry and mechanical properties of the damaged or mis-machined components can be repaired using LAR without deteriorating the performance of the body parts. Compared with traditional repair technologies [ 12 , 13 , 14 ], such as electrobrush plating, thermal spraying, and argon arc welding, LAR has the advantages of a high degree of automation, a small heat affected zone, metallurgical bonding between the repaired zones and the body part, and a reasonable repair cost [ 15 ]. A number of metallic components made of different type of materials, including stainless steel, cobalt-based alloys, titanium alloys, and nickel-based alloys, have been repaired using LAR technology [ 16 , 17 , 18 ].…”