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Component repair using additive manufacturing: experiments and thermal modeling

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Abstract

The objective of this work is to propose an advanced automated damage detection and damage reconstruction algorithm for damaged gear tooth repair. It can automate tool path design and provide precise repair volume detection for complex repair volume. First, models of the damaged and nominal parts were obtained by reverse engineering. Next, the damaged model was aligned with the nominal model. After that, both models were sliced into layers, and a set of parallel and equidistant casting rays was used to intersect with these layers to extract the repair volume. Then the repair tool path was generated and used to guide the laser additive manufacturing process for repair. The corresponding repair experiment and validated numerical model based on repairing a complex gear fracture was conducted to evaluate the reconstruction algorithm efficiency and repair part quality. Microstructure analysis and Vickers hardness test were carried out to evaluate the repaired part quality. The coincidence of scanning points between repaired model and the nominal model is high. The repair experiment confirmed the strong efficiency of this repair algorithm for complex geometry repair. A 3D finite element model was also developed to simulate the repair process and provide critical deformation and residual stress of the repaired parts. The predicted temperature and residual stress results were compared and showed a good agreement with the experimental measurements. These results further validated that the proposed repair algorithm and simulation model are suitable and efficient for the automated repair of damaged components.

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The data that support the findings of this study are available on request.

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Acknowledgments

This project was supported by National Science Foundation Grants CMMI-1547042 and CMMI 1625736, and the Intelligent Systems Center, Center for Aerospace Manufacturing Technologies, and Material Research Center at Missouri S&T. Their financial support is greatly appreciated.

Funding

This project was funded by US National Science Foundation [grants numbers CMMI-1547052, CMMI-1625736]. We also appreciate the financial support provided by the Center for Advanced Manufacturing Technologies and Intelligent Systems Center at the Missouri S&T.

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Authors and Affiliations

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

    Lan Li, Xinchang Zhang, Tan Pan & Frank Liou

  2. Idaho National Laboratory, Idaho Falls, ID, 83415, USA

    Xinchang Zhang

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  1. Lan Li
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  2. Xinchang Zhang
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  3. Tan Pan
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  4. Frank Liou
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Correspondence to Xinchang Zhang.

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Li, L., Zhang, X., Pan, T. et al. Component repair using additive manufacturing: experiments and thermal modeling. Int J Adv Manuf Technol 119, 719–732 (2022). https://doi.org/10.1007/s00170-021-08265-y

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  • DOI: https://doi.org/10.1007/s00170-021-08265-y

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