Repairing surface defects of metal parts by groove machining and wire + arc based filling

Abstract

An approach to repairing surface defects of metal parts is proposed, which includes a combined application of (i) groove machining, (ii) wire and arc additive manufacturing (WAAM), and (iii) finishing machining. The completed analysis revealed that (i) the inclination angle of the groove to be machined is strongly influenced by the manufacturing parameters of the WAAM process, and (ii) the WAAM process models designed for fabricating parts on a flat substrate are not appropriate for filling grooves. To overcome these issues, this research investigated the range of variation of the proper inclination angle of the groove. A mathematical model was developed to determine the manufacturing parameters of WAAM that result in a proper filling of the groove. The effectiveness of the proposed fundamentals was investigated in a case study. The experimental results showed that using the proposed approach and the chosen manufacturing parameters resulted in a complete filling of the machined groove. The fabrication error of the main part of the repaired region before the finishing machining was less than 0.3 mm, while the 'buy-to-fly' ratio of the deposited material was 92.1%. The proposed approach for morphological repair lends itself to a computer-aided automatic part repair process.

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

“…Reduced consumption of CRMs can also be obtained using repair welding and repair additive manufacturing of worn out or damaged products, so the need for new parts is significantly reduced [ 225 , 226 ]. This option is increasingly utilized in the industrial tooling sector, where an improved repair welding (cladding) technology and proper selection of materials can lead to the restoration of the tool several times.…”

Hybrid additive manufacturing of steels and alloys

“…Gas Metal Arc-Welding (GMAW) 3D printing, also named as Wire Arc Additive Manufacturing (WAAM) [32], is closely related to single-layer multi-pass welding. Table 4 demonstrates that energy efficiency of arc welding processes such as the Gas Metal Arc Welding (GMAW) or Gas Tungsten Arc Welding (GTAW) Ti-alloys, Ni-alloys [40,41] CNC as post processing for AM parts SS316L, tool steels Al6061; Ti-6Al-4V; Nisuper-alloys; Brass [42] Combination of different AM types SS316L Ti-alloys resin, polymers (PLA, PET), ceramics; Cu-alloys, Ni-alloys [43][44][45][46] Hybrid machine À single process SS316L Inconel [47] processes can be up to 90% [56]. That is much higher comparing with the poor energy efficiency of laser and electron beam [56,57].…”

“…It can be concluded, that DED techniques using WAAM, DEBW, and LENS ® are beneficial for hybrid AM in terms of surface defects repairing [40,41], productivity, rapid processing of weldable materials; manufacturing of medium and big components with complex geometry and internal configuration; and cost competitiveness [29,32,61].…”

Experimental investigation of the fatigue crack growth behavior in wire arc additively manufactured ER100S‐1 steel specimens

“…5 In addition to the fabrication of new parts, the WAAM technique also facilitates the repair of damaged structures, as an alternative to the replacement of the entire component. 6,7 Similarly to all AM techniques, as well as all the advantages mentioned for WAAM, this technique may also involve some disadvantages. The main disadvantage of such a fabrication method is the possibility of relatively high roughness on the outer surface of the as-built parts and dimensional inaccuracies that may impose the requirement of further post-deposition treatments such as surface machining, high pressure rolling, etc.…”