Abstract: A method of repairing a part with a directed energy deposition (DED) repair operation includes identifying a repair zone on the part. The repair zone represents a region that includes at least one zone of operational wear or damage requiring the DED repair operation. A layer of repair material is applied to the repair zone and the repair zone is preheated using a first energy source. The layer of repair material in the repair zone is melted using a second energy source and is permitted to cool and solidify. The applying, preheating, melting, and cooling steps are repeated a desired number of times to accomplish the desired repair. Use of the first energy source and the second energy source results in a temperature-affected zone that does not extend beyond the repair zone such that heat-sensitive portions of the part do not experience distortion that exceeds allowable tolerances.

Abstract: A method of weld repairing an original part includes inspecting the original part to identify a worn or defective feature requiring repair, removing from the original part the worn or defective feature requiring repair, fabricating a replacement feature, joining the replacement feature to the original part to complete a desired repair, and returning the original part to service after completion of the desired repair. The replacement part is made with a powder beam fusion (PBF) technique. The replacement feature is joined to the original part using a directed energy deposition (DED) joining technique The original part and replacement feature are made from a base material.

Abstract: A method of repairing an aerospace part including inspecting the aerospace part, made from a base material, to identify a worn or defective repair region that requires repair. A sacrificial backing material, which serves as a platform for deposition of repair layers during a repair procedure, is attached to the aerospace part. A repair procedure is performed on the repair region using a directed energy deposition (DED) energy/powder head after which the sacrificial backing material is removed from the aerospace part and the aerospace part is returned to service.

Abstract: An aerospace part, which is made from a base material, repairing using directed energy deposition (DED) techniques. The aerospace part is inspected to identify a worn or defective repair region on a repair feature that requires repair. An intervening feature that blocks line-of-sight from a DED laser/powder head to the repair region on the repair feature is removed such that after removal of the intervening feature there is line-of-sight from the DED laser/powder head to the repair region on the repair feature. a repair procedure is performed on the repair region of the repair feature using the DED laser/powder head. A replacement intervening feature is obtained and attached to the aerospace part to complete a desired repair. The aerospace part is returned to service after completion of the desired repair.

Abstract: An aerospace part, which is made from a base material, is inspected to identify a worn or defective repair region that requires repair. A repair procedure is performed on the repair region using a directed energy deposition (DED) energy/powder head. The repair procedure includes depositing, using the DED energy/powder head, a first layer of DED powder material in the repair region; melting and consolidating, using energy from the DED energy/powder head, the first layer of DED powder material to form a first repair layer having a first pre-determined residual stress state; and repeating the depositing and melting and consolidating steps to create a desired plurality of repair layers. Each of the plurality of repair layers has a pre-determined residual stress state.

Abstract: An aerospace part, which is made from a base material, is inspected to identify a worn or defective repair region that requires repair. A repair procedure is performed on the repair region using a directed energy deposition (DED) energy/powder head. The repair procedure includes depositing, using the DED energy/powder head, a first layer of DED powder material in the repair region; melting and consolidating, using energy from the DED energy/powder head, the first layer of DED powder material to form a first repair layer having a first pre-determined microstructure; and repeating the depositing and melting and consolidating steps to create a desired plurality of repair layers. Each of the plurality of repair layers has a pre-determined microstructure.