Additive repair design process for aluminium components

Additive Manufacturing is considered as one of the most modern manufacturing techniques, and using this technique in components repair is considered as the state of the art in the industry of repairing. The principle of additive repair is to add layers of the metal powder over pre-existing substrate metal. Many companies worked in the field of additive repair, but there is no clear common methodology or process that describes the whole repair process from a re-design of the damaged volume of a component (when required) till the building of it. Therefore, in this work an additive repair design process has been introduced. In addition, it considers the design of the interface zone between the added volume and the substrate metal of the damaged component. The concept of this process consists of three phases, metals database, design and analysis as well as manufacturing and testing.