526
M. Matsumoto et al.
Fig. 36.8 Directed energy deposition (DED) process
binder jetting, powder bed fusion, sheet lamination, and directed energy deposition
(DED). Of these, DED is well suited for remanufacturing as it can create a desired
geometry along an arbitrary trajectory (Matsumoto et al. 2016; Yang et al. 2018).
DED uses a focused thermal energy beam to melt and fuse materials. The typical
DED process is illustrated in Fig. 36.8. Here the thermal energy beam is usually
laser or electron beam. The materials added are typically in the form of the powder
injected into the fusing zone with a flow of powder and inert gas through a nozzle.
36.4.2 Applications of Metal 3D Printing
in Remanufacturing: A Review
Metal 3D printing applications in remanufacturing are still in an immature stage;
most are in the R&D stage.
Research has been undertaken most actively in the aerospace sector. The companies and research organizations have applied DED to the repair of various aircraft
components, including turbine blades, blade disks (blisks), compressor drums,
compressor seals, mobiles, drive shafts, drive couplers, titanium components, etc.
(Ahn 2016; Mudge and Wald 2007). Mudge and Wald, for example, reported the
repair of the worn bearing housing of a gas turbine engine, cost of which was about
50% of a newly manufactured product (Mudge and Wald 2007). They also reported
the repair of a drive shaft and a comparison of the repair by DED and thermal spray.
The hardness and the corrosion resistance of the repaired region by DED were greater
than those of the repaired region by thermal spray (Mudge and Wald 2007). Additionally, the spalling phenomenon was not observed in the region repaired by DED,
whereas severe spalling appeared in the region repaired by thermal spray (Mudge
and Wald 2007). Such a case, the repair cost of DED was approximately 50% that
of the thermal spray (Mudge and Wald 2007).
Similarly, water turbine remanufacturing by DED has been researched. In the
remanufacturing, after measurement of the amount of wear, the additive machine
M. Matsumoto et al.
Fig. 36.8 Directed energy deposition (DED) process
binder jetting, powder bed fusion, sheet lamination, and directed energy deposition
(DED). Of these, DED is well suited for remanufacturing as it can create a desired
geometry along an arbitrary trajectory (Matsumoto et al. 2016; Yang et al. 2018).
DED uses a focused thermal energy beam to melt and fuse materials. The typical
DED process is illustrated in Fig. 36.8. Here the thermal energy beam is usually
laser or electron beam. The materials added are typically in the form of the powder
injected into the fusing zone with a flow of powder and inert gas through a nozzle.
36.4.2 Applications of Metal 3D Printing
in Remanufacturing: A Review
Metal 3D printing applications in remanufacturing are still in an immature stage;
most are in the R&D stage.
Research has been undertaken most actively in the aerospace sector. The companies and research organizations have applied DED to the repair of various aircraft
components, including turbine blades, blade disks (blisks), compressor drums,
compressor seals, mobiles, drive shafts, drive couplers, titanium components, etc.
(Ahn 2016; Mudge and Wald 2007). Mudge and Wald, for example, reported the
repair of the worn bearing housing of a gas turbine engine, cost of which was about
50% of a newly manufactured product (Mudge and Wald 2007). They also reported
the repair of a drive shaft and a comparison of the repair by DED and thermal spray.
The hardness and the corrosion resistance of the repaired region by DED were greater
than those of the repaired region by thermal spray (Mudge and Wald 2007). Additionally, the spalling phenomenon was not observed in the region repaired by DED,
whereas severe spalling appeared in the region repaired by thermal spray (Mudge
and Wald 2007). Such a case, the repair cost of DED was approximately 50% that
of the thermal spray (Mudge and Wald 2007).
Similarly, water turbine remanufacturing by DED has been researched. In the
remanufacturing, after measurement of the amount of wear, the additive machine