Additive repair design approach: Case study to repair aluminium base components

DS 87-5 Proceedings of the 21st International Conference on Engineering Design (ICED 17) Vol 5: Design for X, Design to X, Vancouver, Canada, 21-25.08.2017

Year: 2017
Editor: Anja Maier, Stanko Škec, Harrison Kim, Michael Kokkolaras, Josef Oehmen, Georges Fadel, Filippo Salustri, Mike Van der Loos
Author: Zghair, Yousif Amsad; Lachmayer, Roland
Series: ICED
Institution: Leibniz Universität Hannover, Germany
Section: Design for X, Design to X
Page(s): 141-150
ISBN: 978-1-904670-93-3
ISSN: 2220-4342


Additive manufacturing is considered one of the modest manufacturing techniques. Using this technique in components repair is the state of the art in the industry of maintenance. This paper introduces an additive repair design approach, with focus on Selective Laser Melting technique, and investigates mechanical properties and the bonding force between the damaged components and the added repaired volume. Various load cases and building directions are discussed, and a selected one is simulated and applied on a case study. The candidate metals of the damaged parts are Al-6082 and Al-7075 alloys, and the used powder to repair with the Selective Laser Melting machine is AlSi10Mg. The analysis carried out by means of a finite element numerical model to estimate the axial loading and the induced stresses. Experimental work is implemented, and all analytical and experimental results are discussed and compared. This work aims to develop scientific basics for parts repair using additive manufacturing technologies. Overall, the additive repair approach promises efficiency, but has to be further advanced in the field of maintenance for components in industry.

Keywords: Design for Additive Repair, Design for Additive Manufacturing (DfAM), Additive Manufacturing, Design methods, Computer Aided Design (CAD)


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