Abstract
Metallic components can gain defects such as dents, cracks, wear, heat checks, deformation, etc., that need to be repaired before reinserting into service for extending the lifespan of these parts. In this study, a hybrid process was developed to integrate reverse engineering, pre-repair processing, additive manufacturing, and material testing for the purpose of part remanufacturing. Worn components with varied defects were scanned using a 3D scanner to recreate the three-dimensional models. Pre-repair processing methods which include pre-repair machining and heat-treatment were introduced. Strategies for pre-repair machining of defects including surface impact damage, surface superficial damage and cracking were presented. Pre-repair heat-treatment procedure for H13 tool steel which was widely used in die/mold application was introduced. Repair volume reconstruction methodology was developed to regain the missing geometry on worn parts. The repair volume provides a geometry that should be restored in the additive manufacturing process. A damaged component was repaired using the directed energy deposition process to rebuild the worn geometry. The repaired part was inspected in microstructure and mechanical aspects to evaluate the repair. The hybrid process solved key issues associated with repair, providing a solution for automated metallic component remanufacturing.
Highlights
Components of jet engines, airfoils, piping systems, heavy duty machines, molds, and dies frequently run in harsh conditions such as extreme heat, rapid heating and cooling, dynamic contact, vibration, overload, severe impact, friction, erosion, fatigue, etc. [1,2]
One should notice that the convex hull cannot be result in extra material cut-off in the polygon GMETG. This material over-cut becomes worse when directlyone utilized as theis boundary for machining owing to the possibility of the steep area as shown in deep defect presented while majority defects are shallow
convex-hull boundary (CHB) results in the least amount of cut-off volume
Summary
Components of jet engines, airfoils, piping systems, heavy duty machines, molds, and dies frequently run in harsh conditions such as extreme heat, rapid heating and cooling, dynamic contact, vibration, overload, severe impact, friction, erosion, fatigue, etc. [1,2]. A thin-curved damaged aircraft engine blade was repaired in [10] by depositing material back to the worn area and followed by CNC milling for post-machining. H132 tool steelmethodologies before and after re-hardening repair of typical defects including surface impact indentations, surface superficial defects machining of typical including surface impact indentations, surface superficial defects and process aremachining compared todefects validate the benefits of pre-repair heat-treatment. H13 tool steel which is widely damage reconstruction methodology to recreate the missing geometry on worn parts. ToolH13 steel before after re-hardening process experiments and repair quality inspection are conducted in 5 to evaluate the remanufacturing process are compared to validate the of benefits of pre-repair heat-treatment.
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