An Integrated Framework for Aerospace Components Repair Using Hybrid Laser Wire Additive Manufacturing and Machining

Abstract

The maintenance of mission-critical aircraft engine components faces significant challenges due to the high cost and long lead times associated with spare parts, particularly those made from high-performance alloys such as Inconel 625. This research aims to develop an integrated hybrid manufacturing framework that ensures precise restoration of part geometry and consistency in mechanical properties while minimizing inventory costs through on-demand repair. The framework combines 3D scanning, CAD/CAM, additive manufacturing, and machining to restore damaged parts to their original specifications efficiently and cost-effectively. The approach is divided into three phases. The first phase utilizes an integrated 3D scanning, computer-aided design/manufacturing (CAD/CAM), additive manufacturing, and machining to accurately repair damaged parts. The second phase involves process parameter optimization through experimental design to ensure that the repaired part’s mechanical properties meet functional requirements. The third phase employs a cost model to evaluate the economic benefits of the repair procedure. Our results demonstrate significant cost reductions and favorable mechanical properties, with all outcomes meeting the acceptance thresholds for the component specification. This study shows that the proposed framework provides a sustainable, cost-effective solution for aerospace part repair, offering a viable alternative to part replacement.