Skip to main content
SpringerLink
Log in

Damage reconstruction from tri-dexel data for laser-aided repairing of metallic components

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The laser-assisted additive manufacturing process for component repair requires the repair volume to generate the tool path for building up specific material in the worn area. This paper introduces a damage reconstruction algorithm benefits from tri-dexel modeling. At first, nominal and damaged models were acquired through robot-aided 3D scanning process. Then, damaged models were aligned with nominal models by aligning the associated features using the least-squares method. The area covering the defective region was manually selected, and the minimum bounding box of the area was defined and subsequently sliced into a number of grids according to a user-defined grid interval. After that, rays were projected from each grid node in three orthogonal directions to intersect the selected region of nominal and damaged models. Point set in the damaged zone was extracted by comparing intersections of rays with nominal and damaged models. STereoLithography model of damage was reconstructed based on extracted point cloud using Screened Poisson Surface Reconstruction algorithm. Reconstructed damage was compared with real damage to test the accuracy of the damage reconstruction process. Regained damage was sliced into layers to generate the tool path for material deposition. Repair experiments were conducted to deposit materials in the defective area. Illustrating examples were implemented at last to test the functionality and reliability of the proposed methodology.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Zhang X, Li W, Chen X, Cui W, Liou F (2017) Evaluation of component repair using direct metal deposition from scanned data. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-017-1455-y

  2. Morgan HD, Cherry JA, Jonnalagadda S, Ewing D, Sienz J (2016) Part orientation optimisation for the additive layer manufacture of metal components. Int J Adv Manuf Technol 86:1679–1687. https://doi.org/10.1007/s00170-015-8151-6

    Article  Google Scholar 

  3. Penaranda X, Moralejo S, Lamikiz A, Figueras J (2017) An adaptive laser cladding methodology for blade tip repair. Int J Adv Manuf Technol 92:4337–4343. https://doi.org/10.1007/s00170-017-0500-1

    Article  Google Scholar 

  4. Mançanares CG, de S. Zancul E, da Silva J, Cauchick Miguel PA (2015) Additive manufacturing process selection based on parts’ selection criteria. Int J Adv Manuf Technol 80:1007–1014. https://doi.org/10.1007/s00170-015-7092-4

    Article  Google Scholar 

  5. Baufeld B, Biest O, Van d, Gault R (2010) Additive manufacturing of Ti–6Al–4V components by shaped metal deposition: microstructure and mechanical properties. Mater Des 31:S106–S111. https://doi.org/10.1016/j.matdes.2009.11.032

    Article  Google Scholar 

  6. Dutta B, Froes FH(S) (2017) The additive manufacturing (AM) of titanium alloys. Met Powder Rep 72:96–106. https://doi.org/10.1016/j.mprp.2016.12.062

    Article  Google Scholar 

  7. Dinda GP, Dasgupta AK, Mazumder J (2009) Laser aided direct metal deposition of Inconel 625 superalloy: microstructural evolution and thermal stability. Mater Sci Eng A 509:98–104. https://doi.org/10.1016/j.msea.2009.01.009

    Article  Google Scholar 

  8. Jia Q, Gu D (2014) Selective laser melting additive manufacturing of Inconel 718 superalloy parts: densification, microstructure and properties. J Alloys Compd 585:713–721. https://doi.org/10.1016/j.jallcom.2013.09.171

    Article  Google Scholar 

  9. Lin WC, Chen C (2006) Characteristics of thin surface layers of cobalt-based alloys deposited by laser cladding. Surf Coatings Technol 200:4557–4563. https://doi.org/10.1016/j.surfcoat.2005.03.033

    Article  Google Scholar 

  10. Imran MK, Masood SH, Brandt M, Bhattacharya S, Mazumder J (2011) Direct metal deposition (DMD) of H13 tool steel on copper alloy substrate: evaluation of mechanical properties. Mater Sci Eng A 528:3342–3349. https://doi.org/10.1016/j.msea.2010.12.099

    Article  Google Scholar 

  11. Bhattacharya S, Dinda GP, Dasgupta AK, Mazumder J (2011) Microstructural evolution of AISI 4340 steel during direct metal deposition process. Mater Sci Eng A 528:2309–2318. https://doi.org/10.1016/j.msea.2010.11.036

    Article  Google Scholar 

  12. Li W, Chen X, Yan L, Zhang J, Zhang X, Liou F (2017) Additive manufacturing of a new Fe-Cr-Ni alloy with gradually changing compositions with elemental powder mixes and thermodynamic calculation. Int J Adv Manuf Technol 95:1013–1023. https://doi.org/10.1007/s00170-017-1302-1

    Article  Google Scholar 

  13. Kumar S, Sharma V, Choudhary AKS, Chattopadhyaya S, Hloch S (2013) Determination of layer thickness in direct metal deposition using dimensional analysis. Int J Adv Manuf Technol 67:2681–2687. https://doi.org/10.1007/s00170-012-4683-1

    Article  Google Scholar 

  14. Shamsaei N, Yadollahi A, Bian L, Thompson SM (2015) An overview of direct laser deposition for additive manufacturing; part II: mechanical behavior, process parameter optimization and control. Addit Manuf 8:12–35. https://doi.org/10.1016/j.addma.2015.07.002

    Article  Google Scholar 

  15. Wang Z, Guan K, Gao M, Li X, Chen X, Zeng X (2012) The microstructure and mechanical properties of deposited-IN718 by selective laser melting. J Alloys Compd 513:518–523. https://doi.org/10.1016/j.jallcom.2011.10.107

    Article  Google Scholar 

  16. Bennett J, Dudas R, Cao J et al (2016) Control of heating and cooling for direct laser deposition repair of cast iron components. Int Symp Flex Autom ISFA 2016:229–236. https://doi.org/10.1109/ISFA.2016.7790166

    Google Scholar 

  17. Pinkerton a J, Wang W, Li L (2008) Component repair using laser direct metal deposition. Proc Inst Mech Eng Part B J Eng Manuf 222:827–836. https://doi.org/10.1243/09544054JEM1008

    Article  Google Scholar 

  18. Liu Q, Wang Y, Zheng H, Tang K, Li H, Gong S (2016) TC17 titanium alloy laser melting deposition repair process and properties. Opt Laser Technol 82:1–9. https://doi.org/10.1016/j.optlastec.2016.02.013

    Article  Google Scholar 

  19. Song L, Zeng G, Xiao H, Xiao X, Li S (2016) Repair of 304 stainless steel by laser cladding with 316L stainless steel powders followed by laser surface alloying with WC powders. J Manuf Process 24:116–124. https://doi.org/10.1016/j.jmapro.2016.08.004

    Article  Google Scholar 

  20. Song J, Deng Q, Chen C, Hu D, Li Y (2006) Rebuilding of metal components with laser cladding forming. Appl Surf Sci 252:7934–7940. https://doi.org/10.1016/j.apsusc.2005.10.025

    Article  Google Scholar 

  21. Gao J, Chen X, Yilmaz O, Gindy N (2008) An integrated adaptive repair solution for complex aerospace components through geometry reconstruction. Int J Adv Manuf Technol 36:1170–1179. https://doi.org/10.1007/s00170-006-0923-6

    Article  Google Scholar 

  22. Wilson JM, Piya C, Shin YC, Zhao F, Ramani K (2014) Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis. J Clean Prod 80:170–178. https://doi.org/10.1016/j.jclepro.2014.05.084

    Article  Google Scholar 

  23. Zheng J, Li Z, Chen X (2006) Worn area modeling for automating the repair of turbine blades. Int J Adv Manuf Technol 29:1062–1067. https://doi.org/10.1007/s00170-003-1990-6

    Article  Google Scholar 

  24. Hong-Seok P, Mani TU (2014) Development of an inspection system for defect detection in pressed parts using laser scanned data. Procedia Eng 69:931–936. https://doi.org/10.1016/j.proeng.2014.03.072

    Article  Google Scholar 

  25. He J, Li L, Li J (2011) Research of key-technique on automatic repair system of plane blade welding. In: 2011 Int. Conf. Control. Autom. Syst Eng:1–4

  26. Zhang X, Li W, Liou F (2017) Damage detection and reconstruction algorithm in repairing compressor blade by direct metal deposition. Int J Adv Manuf Technol 95:2393–2404. https://doi.org/10.1007/s00170-017-1413-8

    Article  Google Scholar 

  27. Van Hook T (1986) Real-time shaded NC milling display. In: Proc. 13th Annu. Conf. Comput. Graph. Interact. Tech. ACM, New York, NY, pp 15–20

  28. Ren Y, Lai-Yuen SK, Lee Y-S (2006) Virtual prototyping and manufacturing planning by using tri-dexel models and haptic force feedback. Virtual Phys Prototyp 1:3–18. https://doi.org/10.1080/17452750500283590

    Article  Google Scholar 

  29. Peng X, Zhang W (2009) A virtual sculpting system based on triple Dexel models with haptics. Comput Aided Des Appl 6:645–659. https://doi.org/10.3722/cadaps.2009.645-659

    Article  Google Scholar 

  30. Leu MC, Peng X, Zhang W (2005) Surface reconstruction for interactive modeling of freeform solids by virtual sculpting. CIRP Ann 54:131–134. https://doi.org/10.1016/S0007-8506(07)60066-3

    Article  Google Scholar 

  31. Zhu W, Lee Y-S (2004) Dexel-based force–torque rendering and volume updating for 5-DOF haptic product prototyping and virtual sculpting. Comput Ind 55:125–145. https://doi.org/10.1016/j.compind.2004.07.003

    Article  Google Scholar 

  32. Gao X, Zhang S, Hou Z (2007) Three Direction DEXEL Model of Polyhedrons and Its Application. In: Third Int. Conf. Nat. Comput. (ICNC 2007). pp 145–149

  33. He S, Zeng X, Yan C, et al (2017) Tri-Dexel model based geometric simulation of multi-axis additive manufacturing. In: Huang Y, Wu H, Liu H, yin Z (eds) Intell. Robot. Appl. 10th Int. Conf. ICIRA 2017, Wuhan, China, august 16--18, 2017, proceedings, part III. Springer international publishing, Cham, pp 819–830

  34. Choi SH, Chan AMM (2004) A virtual prototyping system for rapid product development. Comput Des 36:401–412. https://doi.org/10.1016/S0010-4485(03)00110-6

    Google Scholar 

  35. Liu R, Wang Z, Liou F (2017) Multifeature-fitting and shape-adaption algorithm for component repair. J Manuf Sci Eng 140:21003–21019

    Article  Google Scholar 

  36. Kazhdan M, Hoppe H (2013) Screened Poisson surface reconstruction. ACM Trans Graph 32(29):1–29:13. https://doi.org/10.1145/2487228.2487237

    Article  MATH  Google Scholar 

Download references

Acknowledgments

The support from NSF grants CMMI-1547042, CMMI-1625736, EEC-1004839, and Center for Energy Technology and Strategy, National Cheng Kung University, and National Chung-Shan Institute of Science and Technology are appreciated. We also appreciate the financial support provided by the Intelligent Systems Center (ISC) at the Missouri University of Science and Technology.

Author information

Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO, 65409, USA

    Xinchang Zhang, Wei Li & Frank Liou

  2. Department of Material Science and Engineering, Penn State University, University Park, PA, 16801, USA

    Katelyn M. Adkison

Authors
  1. Xinchang Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Wei Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Katelyn M. Adkison
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Frank Liou
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Xinchang Zhang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, X., Li, W., Adkison, K.M. et al. Damage reconstruction from tri-dexel data for laser-aided repairing of metallic components. Int J Adv Manuf Technol 96, 3377–3390 (2018). https://doi.org/10.1007/s00170-018-1830-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-1830-3

Keywords

Search

Navigation