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Exploratory study of repairing damaged aluminum part through robotic hybrid wire arc additive manufacturing and machining for potential in-space manufacturing.
To develop an innovative metallic part repairing in space where gravity is much lower, this paper presents a comprehensive approach for repairing damaged aluminum alloy parts using a robot arm-based hybrid manufacturing platform incorporated wire arc additive manufacturing (WAAM) and milling machining. Initially, 3D models of both undamaged original part and damaged part were obtained through reverse engineering. Then, utilizing Boolean operations, the damaged areas were isolated and reconstructed digitally. Subsequently, printing paths were designed to selectively deposit aluminum 5356 (Al5356) wire onto the damaged regions using WAAM. Next, milling machining, as a post-treatment, was employed to enhance the surface quality of the repaired parts. Finally, tensile tests were conducted to investigate the mechanical properties of the repaired areas. Results demonstrate the feasibility and effectiveness of the proposed repair approach through hybrid manufacturing processes, highlighting its potential for cost-effective and resource-efficient restoration of Al5356 metal parts. Furthermore, the proposed repair process incorporates reverse engineering, making this approach versatile and applicable to the repair of various types of damaged metal parts, especially in space where resources are limited and expensive to obtain.
Additive Research
For On-site Repair AM application..!!
For Powder based AM application..!!
For biological AM application..!!
WAAM process of Aluminum computational modeling and analysis.
DED, and Hybrid AM process computational modeling and analysis.
Extrusion 3D Bioprinting modeling of high viscous biomaterials.
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Comprehensive Advanced Manufacturing (CAM) Laboratory ECSW 4.425 The University of Texas at Dallas 800 W. Campbell Rd., Richardson, TX 75080