Development of depositions strategies for edge repair using a WAAM process

Abstract

Remanufacturing is an industrial process able to restore a component to at least its original performance, and it is considered one of the key processes to support the transition to circular economy. For restoring a metal component, additive manufacturing processes based on Direct Energy Deposition (DED) techniques are the most widely used, since they can process a damaged part with a complex geometry. Among these, Wire Arc Additive Manufacturing (WAAM) has several advantages including a high deposition rate, lower operative, material, and equipment costs. Nevertheless, it is also characterized by low accuracy and a high risk of defects if the process is not tuned correctly. It is therefore crucial to develop smart deposition strategies to ensure defect-free deposition and high efficiency. This study focuses on the repair of steel edges, and specific toolpaths has been designed and tested for repairing this geometrical feature, both concave and convex, coupled with the selection of proper welding parameters and torch tilting angle.