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<p>In-space manufacturing (ISM) is gaining more momentum as space explorations and commercialization expand. This trend emphasizes the importance of developing and optimizing advanced repair and manufacturing techniques for critical components in challenging environments. In this paper, to study the influence of printing paths and tilt angles on the repair quality of bonding areas, a robotic wire arc additive manufacturing (WAAM) platform was adopted to repair damaged aluminum components with aluminum 5356 (Al5356) wire. First, reverse engineering was utilized to obtain the CAD model of the damaged regions for tool path design. Two printing paths were then used to repair the same damaged parts to compare their effectiveness and figure out the better one. Then, using the optimized path, damaged components were repaired with four different tilt angles. To evaluate the influence of tilt angles on the repair quality of the interface between the repaired region and the original substrate, wire electrical discharge machining (wire EDM) was employed to cut the repaired parts and expose the internal structures for microscopic inspection. The experiments revealed that a printing path parallel to the surfaces of the damaged areas with a tilt angle of 140° generated a better interface with a sufficient joint. This can lead to the smallest crack area (0.93%) at the bonding surface. This means the bond was stronger and the repaired part was more solid than with other setups.</p>

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Repairing aerospace aluminum alloy with robotic wire arc additive manufacturing for the potential in-space use

  • 期刊论文

  • 发表日期：

    2025年8月7日

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  • Benquan Li,
  • Lena Le,
  • Jose Rodriguez,
  • Kennedy Constancia Donovan,
  • Yingjian Liu,
  • Jie Zhang,
  • Yi Tian,
  • Wei Li

摘要

In-space manufacturing (ISM) is gaining more momentum as space explorations and commercialization expand. This trend emphasizes the importance of developing and optimizing advanced repair and manufacturing techniques for critical components in challenging environments. In this paper, to study the influence of printing paths and tilt angles on the repair quality of bonding areas, a robotic wire arc additive manufacturing (WAAM) platform was adopted to repair damaged aluminum components with aluminum 5356 (Al5356) wire. First, reverse engineering was utilized to obtain the CAD model of the damaged regions for tool path design. Two printing paths were then used to repair the same damaged parts to compare their effectiveness and figure out the better one. Then, using the optimized path, damaged components were repaired with four different tilt angles. To evaluate the influence of tilt angles on the repair quality of the interface between the repaired region and the original substrate, wire electrical discharge machining (wire EDM) was employed to cut the repaired parts and expose the internal structures for microscopic inspection. The experiments revealed that a printing path parallel to the surfaces of the damaged areas with a tilt angle of 140° generated a better interface with a sufficient joint. This can lead to the smallest crack area (0.93%) at the bonding surface. This means the bond was stronger and the repaired part was more solid than with other setups.