A Hybrid Process Integrating Reverse Engineering, Pre-Repair Processing, Additive Manufacturing, and Material Testing
Xinchang Zhang1, Wenyuan Cui2, Wei Li3
1Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409, USA. xz25c@mst.edu.
Materials (Basel, Switzerland)
|June 21, 2019
Summary
This study introduces a hybrid process for remanufacturing metallic components, integrating reverse engineering, additive manufacturing, and testing. This method effectively repairs defects, extending component lifespan and enabling automated part restoration.
Area of Science:
- Materials Science and Engineering
- Manufacturing Technology
- Mechanical Engineering
Background:
- Metallic components accumulate defects like wear and cracks during service, necessitating repair for extended lifespan.
- Traditional repair methods can be labor-intensive and may not fully restore component integrity.
- Automated remanufacturing is crucial for efficient and sustainable industrial practices.
Purpose of the Study:
- To develop and evaluate a hybrid process for remanufacturing metallic components with various defects.
- To integrate reverse engineering, pre-repair processing, additive manufacturing, and material testing into a unified workflow.
- To provide a solution for automated metallic component remanufacturing.
Main Methods:
- Utilized 3D scanning for reverse engineering of worn components.
- Implemented pre-repair processing including machining strategies for defects and heat treatment for H13 tool steel.
- Developed repair volume reconstruction for additive manufacturing.
- Employed directed energy deposition (DED) for rebuilding worn geometry.
- Conducted microstructural and mechanical inspections to evaluate repair quality.
Main Results:
- Successfully recreated 3D models of defective components.
- Established pre-repair machining and heat treatment procedures for specific defects and materials.
- Developed a methodology for defining repair volumes for additive manufacturing.
- Repaired a damaged component using DED, restoring its geometry.
- Validated the effectiveness of the hybrid process through microstructural and mechanical analysis.
Conclusions:
- The developed hybrid process effectively addresses key challenges in metallic component repair.
- This integrated approach offers a viable solution for automated metallic component remanufacturing.
- The study demonstrates the potential for extending the service life of critical metallic parts through advanced repair techniques.
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