A system (50) and method (200) for repairing one or more components (70) using an additive manufacturing process includes securing the components (70) in a tooling assembly (52) such that a repair surface (72) of each component (70) is positioned within a single build plane (82), determining a repair toolpath (76) corresponding to the repair surface (72) of each component using a vision system (56), depositing a layer of additive powder (72) over the repair surface (72) of each component (70) using a powder dispensing assembly (112), and selectively irradiating the layer of additive powder (72) along the repair toolpath (76) to fuse the layer of additive powder (72) onto the repair surface (72) of each component (70).

A three-dimensional deposition device and a three-dimensional deposition device method are provided. Included are: a powder passage and a nozzle injection opening that supply a powder toward a working surface of an object to be processed; a laser path that irradiates the powder with a laser beam to sinter or melt and solidify at least a part of the powder irradiated with the laser beam so as to form formed layers; a rotation table unit serving as an irradiation angle changing unit that changes an irradiation angle of the laser beam emitted from the laser path to the working surface; and a controller that controls the rotation table unit so that the irradiation angle on an overhanging side with respect to the working surface is less than 90° in a range in which the formed layers can be formed.

A three-dimensional deposition device and a three-dimensional deposition device method are provided. Included are: a powder passage and a nozzle injection opening that supply a powder toward a working surface of an object to be processed; a laser path that irradiates the powder with a laser beam to sinter or melt and solidify at least a part of the powder irradiated with the laser beam so as to form formed layers; a rotation table unit serving as an irradiation angle changing unit that changes an irradiation angle of the laser beam emitted from the laser path to the working surface; and a controller that controls the rotation table unit so that the irradiation angle on an overhanging side with respect to the working surface is less than 90° in a range in which the formed layers can be formed.

A tooling assembly and method of aligning a plurality of components for a repair process in an additive manufacturing machine includes positioning the plurality of components such that a repair surface of each of the plurality of components contacts an alignment plate, e.g., under the force of gravity or using biasing members. The method further includes surrounding the alignment plate with containment walls to define a reservoir around the plurality of components and dispensing a fill material, such as wax or a potting material, into the reservoir which is configured for fixing a relative position of the plurality of components when the fill material is solidified.

Embodiments of the present invention provides an approach for repairing defects in a structure, located in difficult to reach area, by using a self-guiding and self-melting robotic thread. The approach can use an external guidance system to find the target location of the structure and deploy a robotic thread to the defective area. Portion of the robotic thread contains a filler material can have similar materials to the structure. After the system has determined the size, length and volume of the repair, the system calculates the required length of the robotic thread and guides the thread to the defective area. Once the robotic thread is in place, the filler material begins to melt via heat. The filler material, in a melted and pliable state, can flow into the defect area. Once cooled, the filler material can now support the structure.

A method may include controlling, by a computing device, an energy source to form a melt pool at a build surface; and controlling, by the computing device, a material delivery device to direct a powder at the melt pool to form the seal fin comprising a metal matrix composite on the build surface, wherein the metal matrix composite comprises a matrix material and a reinforcement phase.

There is provided a manufacturing method of a Ni-based alloy repaired member having a repair piece formed at a damaged portion of a base material. The base material and the repair piece are made of a high precipitation-strengthened Ni-based alloy material. The manufacturing method includes the steps of: preprocessing a surface of the damaged portion; preparing a Ni-based alloy powder having a predetermined chemical composition; depositing a sprayed piece on the damaged portion by a high-speed collision spraying process using the Ni-based alloy powder; subjecting the sprayed piece to a predetermined heat treatment so that the sprayed piece is thermally refined to a softened sprayed piece; processing the softened sprayed piece into a shaped sprayed piece with a desired shape; and subjecting whole of the shaped sprayed piece and the base material to a predetermined heat treatment so that the shaped sprayed piece is thermally refined to the repair piece.

A method of repairing an airfoil is provided. The method includes providing an airfoil with a damaged section and removing the damaged section by machining or cutting an upper section of the airfoil. A replacement section is configured to mate with an upper surface of the airfoil. A presintered preform is provided to join the airfoil and the replacement sections through a resistance brazing process. The presintered preform is configured to mate with the upper surface of the airfoil and a lower surface of the replacement section and inserted between this upper surface and lower surface, creating a stacked airfoil comprising three mated sections in abutting contact. The stacked airfoil is resistance brazed such that only the braze material of the presintered preform melts and the upper surface of the airfoil and the lower surface of the replacement section remain below the grain boundary temperature of the material of the airfoil.

A method for hard-surfacing metal parts for an aircraft turbofan, the method involving the use of a nozzle outputting a laser beam or an electron beam, which is to heat a sprayed powder for hard-surfacing the metal part, the method including positioning the metal part to be hard-surfaced in an enclosure, the top portion of which has an opening; positioning a mobile cover covering the opening of the top portion, the mobile cover having an opening; positioning the nozzle at the opening of the mobile cover; feeding an inert gas into the enclosure; spraying metal powders and emitting the laser or electron beam for hard-surfacing the metal part; moving the nozzle relative to the enclosure along a path for hard-surfacing the metal part, the movement of the nozzle causing the movement of the mobile cover on the top surface of the enclosure.

A method for repairing a drill bit includes: scanning the drill bit after manufacture thereof; comparing the scan to a design model of the drill bit to recognize one or more features of the drill bit, thereby generating a first model of the as-built drill bit; scanning the drill bit after drilling with the drill bit; comparing the scan of the used drill bit to the first model to recognize the features, thereby generating a second model of the used drill bit; simulating a plurality of repair strategies using the first and second models; and selecting one of the repair strategies by comparing results of the simulations.