Application of Directed Energy Deposition-Based Additive Manufacturing in Repair
Source abstract
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.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · Welding Techniques and Residual Stresses
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of Applied Science and Technology, Politecnico di Torino, Corso Duca Degli Abruzzi 24, 10129 Torino, Italy
References (100+)
Show source-provided references
1. The Role of Laser Additive Manufacturing Methods of Metals in Repair, Refurbishment and Remanufacturing—Enabling Circular Economy, Phys
2. Fischedick, M., Roy, J., Abdel-aziz, A., Acquaye, A., Allwood, J.M., Ceron, J.-P., Geng, Y., Kheshgi, H., Lanza, A., and Perczyk, D. (2014). Climate Change 2014: Mitigation of Climate Change. Contribution of Working Group III to the Fifth Assessment Report of the Intergovernmental Panel on Climate Change, Cambridge University Press.
3. Comission, E. (2015). Closing the Loop—An EU Action Plan for the Circular Economy, European Commission.
4. Saboori, A., Gallo, D., Biamino, S., Fino, P., and Lombardi, M. (2017). An Overview of Additive Manufacturing of Titanium Components by Directed Energy Deposition: Microstructure and Mechanical Properties. Appl. Sci., 7.10.3390/app7090883 ↗
5. Rapid manufacturing and rapid tooling with layer manufacturing (LM) technologies, state of the art and future perspectives10.1016/S0007-8506(07)60206-6 ↗
6. An overview of Direct Laser Deposition for additive manufacturing; Part II: Mechanical behavior, process parameter optimization and control
7. Additive Manufacturing of IN100 Superalloy Through Scanning Laser Epitaxy for Turbine Engine Hot-Section Component Repair: Process Development, Modeling, Microstructural Characterization, and Process Control10.1007/s11661-015-2912-6 ↗
8. Microstructure and mechanical behavior of commercial purity Ti/Ti–6Al–2Zr–1Mo–1V structurally graded material fabricated by laser additive manufacturing10.1016/j.scriptamat.2013.11.002 ↗
9. The metallurgy and processing science of metal additive manufacturing The metallurgy and processing science of metal additive manufacturing10.1080/09506608.2015.1116649 ↗
10. Residual Stress in Metal Additive Manufacturing10.1016/j.procir.2018.05.039 ↗
11. Bosio, F., Saboori, A., Lacagnina, A., Librera, E., de Chirico, M., Biamino, S., Fino, P., and Lombardi, M. (2018, January 14–18). Directed energy deposition of 316L steel: Effect of type of powders and gas related parameters. Proceedings of the Euro PM2018 Congress Exhebition, Bilbao, Spain.
12. Wang, J., Prakash, S., Joshi, Y., and Liou, F.W. (2004). Laser Aided Part Repair-A Review. Solid Free. Fabr. Proc., University of Texas Press.
13. Laser repairing surface crack of Ni-based superalloy components
14. Comparative Study of Co-based Alloys in Repairing Low Cr-Mo steel Components by Laser Cladding10.1016/j.phpro.2012.10.050 ↗
15. X-ray computed tomography for additive manufacturing: A review10.1088/0957-0233/27/7/072001 ↗
16. Component repair using laser direct metal deposition10.1243/09544054JEM1008 ↗
17. Reducing waste: Repair, recondition, remanufacture or recycle?10.1002/sd.271 ↗
18. Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis10.1016/j.jclepro.2014.05.084 ↗
19. Yushchenko, K.A., Savchenko, V.S., Chervyakova, L.V., David, S.A., and Vitek, J.M. (1943). Study of Weldability and Development of the Technology for Repair of High-Nickel Alloy Components, Oak Ridge National Laboratory.
20. Fatigue behaviour of T welded joints rehabilitated by tungsten inert gas and plasma dressing10.1016/j.matdes.2011.06.051 ↗
21. Plasma transferred arc repair welding of the nickel-base superalloy IN-738LC10.1007/s11665-997-0055-7 ↗
22. Restoration of Nickel-Base Turbine Blade Knife-Edges with Controlled Laser Aided Additive Manufacturing10.1016/j.phpro.2011.03.051 ↗
23. Steel coating application for engine block bores by Plasma Transferred Wire Arc spraying process10.1016/j.surfcoat.2014.11.018 ↗
24. Component repair using HVOF thermal spraying10.1016/S0924-0136(99)00113-2 ↗
25. Aoshima, S. (1999). Electro-Spark Process for Repair and Maintenance of Die-Casting Dies, TechnoCoat Int.
26. Evaluation of the mechanical properties of laser cladded hypereutectoid steel rails10.1016/j.wear.2019.202930 ↗
27. Toyserkani, E., Khajepour, A., and Corbin, S.F. (2004). Laser Cladding, Taylor Francis Group. [1st ed.].10.1201/9781420039177 ↗
28. Wire based additive layer manufacturing: Comparison of microstructure and mechanical properties of Ti-6Al-4V components fabricated by laser-beam deposition and shaped metal deposition10.1016/j.jmatprotec.2011.01.018 ↗
29. Singh, H., and Jain, P.K. (2015, January 13–15). Past, present and future the characterization of surface topography of plasmatransferred arc coatings. Proceedings of the Indian Conference on Applied Mechanics, New Delhi, India.
30. Additive manufacturing using plasma transferred arc10.1007/s00170-015-7697-7 ↗
31. Direct metal additive manufacturing processes and their sustainable applications for green technology: A review10.1007/s40684-016-0048-9 ↗
32. Saboori, A., Bosio, F., Librera, E., de Chirico, M., Biamino, S., Lombardi, M., and Fino, P. (2018, January 14–18). Accelerated Process Parameter Optimization for Directed Energy Deposition of 316L Stainless Steel. Proceedings of the Euro PM2018 Congress Exhebition, Bilbao, Spain.
33. Metal Additive Manufacturing: A Review10.1007/s11665-014-0958-z ↗
34. Torims, T. (2013). The Application of Laser Cladding to Mechanical Component Repair, Renovation and Regeneration. DAAAM International Scientific Book 2013, DAAAM International.10.2507/daaam.scibook.2013.32 ↗
35. Gibson, I., Rosen, D., and Stucker, B. (2015). Directed Energy Deposition Processes. Addit. Manuf. Technol. 3D Printing, Rapid Prototyping, Direct Digit. Manuf., Springer.10.1007/978-1-4939-2113-3_10 ↗
36. Mazzucato, F., Tusacciu, S., Lai, M., Biamino, S., Lombardi, M., and Valente, A. (2017). Monitoring Approach to Evaluate the Performances of a New Deposition Nozzle Solution for DED Systems. Technologies, 5.10.3390/technologies5020029 ↗
37. Microhardness and wear resistance of Al2O3-TiB2-TiC ceramic coatings on carbon steel fabricated by laser cladding10.1016/j.ceramint.2018.09.140 ↗
38. Corrosion behavior of plasma sprayed ceramic and metallic coatings on carbon steel in simulated seawater10.1016/j.matdes.2013.06.002 ↗
39. Integration detection of maneuvering target in strong clutter background with high range resolution radar
40. Application of laser cladding technology in surface modification of titanium alloys
41. Advances in laser cladding ceramic particle reinforced metal mateix composite coating technology
42. Development of strength-hardness relationships in additively manufactured titanium alloys10.1016/j.msea.2017.03.102 ↗
43. Microstructure modelling of laser metal powder directed energy deposition of alloy 718
44. Production of Single Tracks of Ti-6Al-4V by Directed Energy Deposition to Determine the Layer Thickness for Multilayer Deposition
45. Microstructure and mechanical behavior of laser additive manufactured AISI 316 stainless steel stringers10.1016/j.matdes.2013.10.016 ↗
46. Laser aided direct metal deposition of Inconel 625 superalloy: Microstructural evolution and thermal stability10.1016/j.msea.2009.01.009 ↗
47. Partitioning of laser energy during directed energy deposition
48. Research and development status of laser cladding on magnesium alloys: A review10.1016/j.optlaseng.2017.02.007 ↗
49. Microstructure and properties of Ti/TiBCN coating on 7075 aluminum alloy by laser cladding10.1016/j.surfcoat.2017.11.034 ↗
50. An investigation into stainless-steel/structural-alloy-steel bimetal produced by shell mould casting10.1016/j.matdes.2008.04.074 ↗
51. Additive manufacturing of steel--bronze bimetal by shaped metal deposition: Interface characteristics and tensile properties10.1007/s00170-013-5191-7 ↗
52. Microstructure and mechanical properties of carbon steel A210–superalloy Sanicro 28 bimetallic tubes10.1016/S0921-5093(02)00686-X ↗
53. Interfacial characterization of SLM parts in multi-material processing: Metallurgical diffusion between 316L stainless steel and C18400 copper alloy10.1016/j.matchar.2014.05.001 ↗
54. Application of Laser Engineered Net Shaping (LENS) to manufacture porous and functionally graded structures for load bearing implants10.1007/s10856-008-3478-2 ↗
55. Characteristics of the bond in Cu–H13 tool steel parts fabricated using SLM10.1016/j.cirp.2008.03.010 ↗
56. The properties and application of bi-metal hot-forging die10.1016/S0924-0136(97)00318-X ↗
57. Characterization of 316L(N)-IG SS joint produced by hot isostatic pressing technique10.1016/S0022-3115(02)00965-0 ↗
58. Electrical and thermal properties of the interface at diffusion-bonded and soldered 304 stainless steel and copper bimetal10.1016/S0924-0136(03)00029-3 ↗
59. Investigation of effect of the stand-off distance on interface characteristics of explosively welded copper and stainless steel10.1016/j.matdes.2007.07.012 ↗
60. Fabrication of high chromium cast iron and medium carbon steel bimetal by liquid–solid casting in electromagnetic induction field10.1016/j.matdes.2011.01.006 ↗
61. Co-extrusion of dissimilar sintered P/M preforms—An explored route to produce bimetallic tubes10.1016/j.msea.2005.06.025 ↗
62. Manufacturing Ti-6Al-4V components by shaped metal deposition: Microstructure and mechanical properties10.1088/1757-899X/26/1/012001 ↗
63. Additive manufacturing of Inconel 718—Ti6Al4V bimetallic structures
64. Stainless steel to titanium bimetallic structure using LENSTM
65. Additive manufacturing of Inconel 718—Copper alloy bimetallic structure using laser engineered net shaping (LENSTM)
66. Seltzer, D., Wang, X., Nassar, A., Schaino, J., and Reutzal, E. (2015, January 10–12). System Identification and Feedback Control for Directed-Energy Metal-Based Additive Manufacturing. Proceedings of the Solid Freeform Fabrication Proceedings, Austin, TX, USA.
67. A Survey of Sensing and Control Systems for Machine and Process Monitoring of Directed-Energy, Metal-Based Additive Manufacturing10.1108/RPJ-12-2014-0177 ↗
68. Camp, J.D., and Bergan, P. (2019, January 2–5). Implementation of Laser Repair Process for Navy Aluminum Components. Proceedings of the Diminishing Manufacturing Sources and Material Shortages Conference, Phoenix, AZ, USA.
69. Bremer, C. (2001, January 28–31). Adaptive Welding Strategies for Repair and Overhaul of Turbine Blades and Blisks. Proceedings of the 3rd LANE, Laser Assisted Net Shape Engineering 3, Erlangen, Germany.
70. An Advanced Repair Technique: Laser Powder Build-up Welding
71. Effect of processing conditions on the microstructure, porosity, and mechanical properties of Ti-6Al-4V repair fabricated by directed energy deposition10.1016/j.jmatprotec.2018.08.041 ↗
72. TC17 titanium alloy laser melting deposition repair process and properties10.1016/j.optlastec.2016.02.013 ↗
73. Laser metal deposition repair applications for Inconel 718 alloy10.1016/j.matpr.2017.08.068 ↗
74. da Sun, S., Liu, Q., Brandt, M., Janardhana, M., and Clark, G. (2012, January 23–28). Microstructure and mechanical properties of laser cladding repair of aisi 4340 steel. Proceedings of the 28th International Congress of the Aeronautical Sciences, Brisbane, Australia.
75. Griffith, M.L. (2000). Understanding the microstructure and properties of components fabricated by laser engineered net shaping (LENSTM). Mat. Res. Soc. Symp. Proc., 625.10.1557/PROC-625-9 ↗
76. Zhu, S., Chen, W., Zhan, X., Ding, L., and Zhou, J. (2018). Parameter optimisation of laser cladding repair for an Invar alloy mould. Proc. Inst. Mech. Eng. Part B: J. Eng. Manuf.10.1177/0954405418805653 ↗
77. Repairing casting part using laser assisted additive metal-layer deposition and its mechanical properties10.1016/j.optlastec.2018.04.007 ↗
78. Experimental characterization of laser cladding of CPM 9V on H13 tool steel for die repair applications10.1016/j.jmapro.2015.06.018 ↗
79. Laser cladding as repair technology for Ti-6Al-4V alloy: Influence of building strategy on microstructure and hardness10.1016/j.matdes.2015.07.035 ↗
80. Additive manufacturing in repair: Influence of processing parameters on properties of Inconel 71810.1016/j.matlet.2019.05.114 ↗
81. Mould steels repaired by laser welding10.1016/j.engfailanal.2008.02.010 ↗
82. Possibility of introducing laser surfacing into maintenance service of die-casting dies10.1016/j.surfcoat.2003.10.101 ↗
83. Laser cladding of rail steel with Co–Cr10.1179/1743294412Y.0000000075 ↗
84. Laser Cladding of Vanadium-Carbide Tool Steels for Die Repair10.1016/j.phpro.2011.03.044 ↗
85. van Rooyen, C., Burger, H., Theron, M., and Doubell, P. (2009, January 15–18). In-situ Crack Repair by Laser Cladding. Proceedings of the Fifth Int. WLT-Conference Lasers Manuf, Munich, Germany.
86. Laser reconditioning of crankshafts: From lab to application10.1016/j.phpro.2010.08.160 ↗
87. Laser Engineered Net Shaping Advances Additive Manufacturing and Repair
88. (2019, July 01). Available online: https://www.kimi-sa.com/marine/diesel-engine-machinery/four-stroke-piston-repair.
89. Residual stress measurements in laser clad repaired low pressure turbine blades for the power industry10.1016/j.msea.2006.04.065 ↗
90. Crack Repair of Single Crystal Turbine Blades Using Laser Cladding Technology10.1016/j.procir.2014.06.151 ↗
91. A repair and overhaul methodology for aeroengine components10.1016/j.rcim.2009.07.001 ↗
92. Laser Repair welding of molds with various pulse shapes
93. Thermal fatigue cracking of surface engineered hot work tool steels10.1016/j.surfcoat.2004.04.053 ↗
94. Causes of failure and repairing options for dies and molds: A review10.1016/j.engfailanal.2013.09.006 ↗
95. Repair effect of hot work tool steel by laser-melting process
96. Failure analysis of hot forging dies for automotive components10.1016/j.engfailanal.2007.10.016 ↗
97. Assessment of laser cladding as an option for repairing/enhancing rails10.1016/j.wear.2015.02.027 ↗
98. Laser Cladding Device for In Situ Repairs of Marine Crankshafts10.4028/www.scientific.net/AMR.765-767.709 ↗
99. Single-crystal turbine blade tip repair by laser cladding and remelting10.1016/j.cirpj.2017.04.001 ↗
100. Modeling of worn surface geometry for engine blade repair using Laser-aided Direct Metal Deposition process10.1016/j.mfglet.2017.11.001 ↗