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Measurement demonstration component provided by Corpus Christi Army Depot (CCAD)
Interest in Laser Powder Feed Directed Energy Deposition (LPFDED) repaired components has grown, but it is still a maturing technology. This project focuses on the development of a LPFDED repair technology that can be cost-effectively and consistently applied to a wide range of high-reliability applications with a certifiable, approval-based method.
There is a need for a reliable and robust additive manufacturing (AM) repair method for military aircraft related components manufactured from Ti-6Al-4V. Depending on the component, conventional repair methods may not always be feasible or reliable. As a result, interest in Laser Powder Directed Energy Deposition (LPDED) to solve this problem has grown. LPDED is a maturing technology, however, lacking specifications, best practices, procedures, and process controls.
The goal of this project was to facilitate the adoption of AM for flight-worthy repairs by restoring the Ti-6Al-4V component function without compromising structural integrity. Restoration of the component function was achieved by the development of an LPDED repair methodology that could be cost-effective and consistently applied to a range of applications. The project also included the coordinated integration of available, past and ongoing, LPDED development efforts into a centralized directed energy database (DEDatabase).
This project consisted of four phases to develop LPDED for certifiable component repair and maintenance: