Evaluation of component repair using direct metal deposition from scanned data

Zhang, Xinchang; Li, Wei; Chen, Xueyang; Cui, Wenyuan; Liou, Frank W.

doi:10.1007/s00170-017-1455-y

Cited by 44 publications

(29 citation statements)

References 28 publications

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“…MAM can build up a new structure or repair damaged parts, making it a sustainable technology optimal for reversing the end-of-life (EoL) of a product by extension usage or second life in a circular economy [32,[44][45][46][47].…”

Section: New Products From Old Ccomponentsmentioning

confidence: 99%

“…Additive manufacturing is rapidly gaining ground in the industrial sector with the help of direct metal laser sintering (DMLS) or direct laser deposition (DLD) technologies, which demonstrate new promising and innovative manufacturing techniques to be used as alternative methods for repairing parts or tools that would otherwise take considerable effort to repair or need to be replaced altogether [45][46][47].…”

Section: New Products From Old Ccomponentsmentioning

confidence: 99%

“…A set of advanced methodologies for the remanufacturing of complex geometry and expensive parts via reverse engineering, free-form surface modelling, laser additive repairs, and machining involves the integration of 3D non-contact scanning methods. It ensures the re-design of damaged parts, adaptive free-form surface reconstruction to create the digital model of a laser additive manufacturing process containing slicing, metrology, path planning, and a subsequent multi-axis machining operation, as shown in the Figure 7 [2,[45][46][47][48][49][50][51].…”

Section: New Products From Old Ccomponentsmentioning

confidence: 99%

“…parts or tools that would otherwise take considerable effort to repair or need to be replaced altogether [45][46][47].…”

Section: New Products From Old Ccomponentsmentioning

confidence: 99%

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A Deep Look at Metal Additive Manufacturing Recycling and Use Tools for Sustainability Performance

et al. 2019

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The present study refers to 3D metal additive manufacturing (MAM) from an interdisciplinary perspective, providing an overview on sustainability, basic principles, and a conceptual framework on environmental performance, implicit constraints regarding materials, recycling and use/reuse tools for extended life cycle, regarded as the trendiest manufacturing processes in terms of material consumptions efficacy and energy efficiency. The demand for integrating MAM technology as a means to boosting sustainability in industry is based on its capacity to use smart or custom-designed materials to generate special geometries, unobtainable otherwise, allowing for further part optimisation or redesign. The outlined advantages and challenges of the new MAM processes and advanced technologies for functional objects and durable products underline the high interest in this area. Results from the literature and our MAM research interest indicate that some metal powder (MP) recycling and use/reuse technologies could be developed to save MP, as could MAM applications in component redesign and repairs to increase sustainability. The achievement has a high degree of generality and serves as a basis for future MAM sustainable methods.

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Section: New Products From Old Ccomponentsmentioning

confidence: 99%

Section: New Products From Old Ccomponentsmentioning

confidence: 99%

Section: New Products From Old Ccomponentsmentioning

confidence: 99%

“…parts or tools that would otherwise take considerable effort to repair or need to be replaced altogether [45][46][47].…”

Section: New Products From Old Ccomponentsmentioning

confidence: 99%

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A Deep Look at Metal Additive Manufacturing Recycling and Use Tools for Sustainability Performance

et al. 2019

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“…Przykłady proszkowego napawania laserowego i frezowania/ /toczenia CNC (a, b) oraz naprawy łopatek (c) [7,18] stowego, bezpośredniego nakładania warstw z obróbką ubytkową), które są wyposażane w skanery laserowe 3D i urządzenia kontrolne (sondy pomiarowe 3D). Kompletny proces hybrydowy obejmuje więc: szybkościowe frezowanie (HSM), skanowanie powierzchni 3D, tworzenie modelu i podział warstw ubytku materiału, napawanie laserowe, kontrolę 3D, usuwanie zadziorów z krawędzi/ /polerowanie i znakowanie laserowe [12,21,22]. Szczegółowy opis cyklu naprawy, zaproponowany w ramach projektu RECLAIM [8,12], przedstawiono na rys.…”

Section: Przykłady Zastosowania Procesów Hybrydowych Am + Sm Cncunclassified

Hybrid manufacturing of metallic parts integrated additive and subtractive processes

Grzesik

2018

Mechanik

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Przedstawiono nową koncepcję hybrydowego kształtowania złożonych wyrobów, bazującą na integracji techniki przyrostowej oraz wykańczającej obróbki ubytkowej na jednej obrabiarce CNC. Ta koncepcja jest intensywnie rozwijana w ramach strategii Produkcja/Wytwarzanie 4.0. Podano zasady i możli-wości technologiczne integracji laserowego napawania proszkowego i wykańczającego toczenia/frezowania w różnych zastosowaniach przemysłowych, takich jak: kształtowanie przyrostowe dodatkowych elementów w złożonych geometrycznie wyrobach, nanoszenie warstw funkcjonalnych oraz naprawa zużytych lub uszkodzonych, dużych i drogich elementów, np. łopatek i obudów turbin lotniczych. Omówiono stosowane strategie technologiczne, programy CAD/CAM i rozwiązania konstrukcyjne obrabiarek hybrydowych CNC. SŁOWA KLUCZOWE: obróbka hybrydowa, obróbka przyrostowa, obróbka ubytkowa CNC, naprawa części, obrabiarki hybrydowe This review paper highlights the hybrid manufacturing processes which integrate the additive and subtractive processes performing on one hybrid platform consisting of the LMD (laser metal deposition) unit and multi-axis CNC machining center. This hybrid technology is rapidly developed and has many applications in Production/Manufacturing 4.0 including the LRT (laser repair technology). In particular, some important rules and advantages as well as technological potentials of the integration of a powder metal deposition and finishing CNC milling/turning operations are discussed and overviewed. Some representative examples such as formation of difficult features around the part periphery, deposition of functional layers and coatings and repair of high-value parts in aerospace industry are provided. Moreover, the technological strategies, CAD/CAM and CAI programs and construction designs of the hybrid manufacturing platforms are explained. Some conclusions and future trends in the implementation of hybrid processes are outlined. KEYWORDS: hybrid machining, additive machining, CNC machining, repair technology, hybrid machine tools Artykuł jest kontynuacją tematu hybrydowej obróbki konwencjonalnej i niekonwencjonalnej, zapoczątkowane-go przez autora w poprzednim wydaniu miesięcznika Mechanik [1]. Autor rozwija problematykę integracji/zespolenia kilku procesów w jednym urządzeniu wytwórczym, nazywanym urządzeniem hybrydowym, które powstało na bazie wielofunkcyjnych obrabiarek CNC do obróbki zintegrowanej/kompletnej (multi-tasking machine tools), takich jak wieloosiowe centra frezarskie czy centra tokarsko-frezarskie (turning-milling centers) [2,3]. Pierwszy etap integracji, który nastąpił na przełomie lat 80. i 90., polegał na zainstalowaniu źródła lasera wspomagającego obróbkę konwencjonalną. Obecnie hybrydyzacja procesów wytwórczych/obróbkowych zakłada prowadzenie na jednym urządzeniu obróbki przyrostowej, czyli addytywnej (additive manufacturing -AM), oraz końcowej/wykańczającej obróbki skrawaniem (subtraktywnej) wraz z automatyczną kontrolą wymiarową [1,3]. Obróbkę addytywną zwykle nazywa się drukowaniem 3D (3D printing).Wachlarz ...

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Microstructure, Mechanical Properties, and Corrosion Behavior of Co‐Based Stellite 6 Multilayer Overlays Deposited on ASTM A36 Steel by Gas Metal Arc Welding Process

Sankarapandian¹,

Kumar

Kannan

et al. 2023

steel research int.

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Hardfacing is an effective method for restoring the damaged part. Herein, cobalt‐based superalloy Stellite‐6 is deposited on A36 substrate using gas metal arc welding process. The mechanical properties, microstructure, and corrosion behavior of Stellite‐6 overlays on A36 substrate are examined. Defect‐free hard overlays are obtained, and a dilution ratio of 19.9% is achieved with weaving technique. X‐ray diffraction analysis reveals the presence of M7C3, M23C6, M6C, and martensite in the Stellite‐6 hard overlays. The microstructure of the deposit contains martensite, carbides, and interdendritic precipitates while the mean hardness is 471 HV0.5. Tensile testing with specimens extracted on the longitudinal (LD) and transverse (TD) orientation of the stellite‐6 deposit shows a strength above 950 MPa along with the brittle nature of fracture. Grain growth is epitaxial and shows dendritic morphologies. The higher fraction of high‐angle grain boundaries improves the tensile strength of the deposit and interface region. The localized corrosion behavior of stellite‐6 hard overlays is found to be excellent, and the corrosion analysis exhibits a corrosion rate of 0.10 mils per year (mpy). The outcomes of the study highlight the feasibility of Stellite‐6 hard overlays for extending the service life of A36 steel in chloride environments.

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Evaluation of component repair using direct metal deposition from scanned data

Cited by 44 publications

References 28 publications

A Deep Look at Metal Additive Manufacturing Recycling and Use Tools for Sustainability Performance

A Deep Look at Metal Additive Manufacturing Recycling and Use Tools for Sustainability Performance

Hybrid manufacturing of metallic parts integrated additive and subtractive processes

Microstructure, Mechanical Properties, and Corrosion Behavior of Co‐Based Stellite 6 Multilayer Overlays Deposited on ASTM A36 Steel by Gas Metal Arc Welding Process

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