Direct laser deposition for re-manufacturing of components

The volume and dimensional loss of components can often result in product failure due to substantial surface degradation. In the current state-of-the-art technology with regards to Laser Metal Deposition (LMS), products are manufactured in compliance with their mechanical properties, but rarely in regards to an anticipated dimensional or volume loss. The simplest mode of wear involves two bodies of material, eventually extending to a configuration of three bodies, accelerating the wear phenomenon. Furthermore, high wear can be combined with other modes of deterioration such as corrosion. Wear modes are categorized in a variety of types including abrasive, seizure, fretting, erosion, cavitation and fracture spalling. The abrasive wear mode is the most severe in the industry. Abrasive wear occur when small particles of material indent the surface creating a scratch by penetrating and indenting the material. The dimensions of the scratch and volume of material removed will be determined by the combination of the hardness of the particle, the force, the temperature, and the speed of the operation. At the current state of modern ceramics and metallurgy wear requirements are satisfied although the finished part with top limit of carbide precipitation at 40-45%, lacks toughness and rigidity. Wear resistance is related to the carbide volume fraction. Worldwide, researchers are investigating and expanding the application of AM for effective part remanufacturing. The majority of the current research is focused on material. However, as the technology evolves, researchers are faced with new challenges in how to effectively use AM processes to achieve the desired functionality in more efficient way.