Review of Directed Energy Deposition (DED) in Component Repair

Directed Energy Deposition (DED) is a groundbreaking technology in the aerospace industry, particularly in repairing components. DED offers precise restoration capabilities with minimal distortion, ensuring that components maintain their original specifications while fostering metallurgical bonding. This paper conducts a comprehensive review of academic and industrial studies to examine the feasibility and effectiveness of DED. DED provides significant advantages over conventional repair methods, showcasing remarkable accuracy in restoring erosion-damaged components such as AM355 steel T700 blisks. The endorsement of industry leaders, such as Rolls-Royce Deutschland's use of DED for repairing worn flanges and damping wire grooves, underscores its potential to deliver substantial returns on investment. Despite these advancements, challenges remain in optimizing process parameters and deposition strategies to further enhance part quality. However, ongoing research initiatives are actively addressing these challenges, positioning DED to become a critical technology in aerospace maintenance and repair operations. This paper offers valuable insights into the current state of DED technology, highlighting its benefits, challenges, and future prospects in aerospace component repair. Ultimately, the widespread adoption of DED promises to revolutionize aerospace maintenance practices, providing cost-effective solutions while minimizing environmental impact.