A systematic review of additive manufacturing-based remanufacturing techniques for component repair and restoration

Hybrid cylindrical roller thrust bearing washers of type 81212 were manufactured by tailored forming. An AISI 1022M base material, featuring a sufficient strength for structural loads, was cladded with the bearing steel AISI 52100 by plasma transferred arc welding (PTA). Though AISI 52100 is generally regarded as non-weldable, it could be applied as a cladding material by adjusting PTA parameters. The cladded parts were investigated after each individual process step and subsequently tested under rolling contact load. Welding defects that could not be completely eliminated by the subsequent hot forming were characterized by means of scanning acoustic microscopy and micrographs. Below the surface, pores with a typical size of ten µm were found to a depth of about 0.45 mm. In the material transition zone and between individual weld seams, larger voids were observed. Grinding of the surface after heat treatment caused compressive residual stresses near the surface with a relatively small depth. Fatigue tests were carried out on an FE8 test rig. Eighty-two percent of the calculated rating life for conventional bearings was achieved. A high failure slope of the Weibull regression was determined. A relationship between the weld defects and the fatigue behavior is likely.

Investigations on Tailored Forming of AISI 52100 as Rolling Bearing Raceway

Improving metal surface integrity by integrating mechanical stress fields during micron- and nano-abrasive machining

The grinding surface mechanical property is important for its working life span, which is determined by the microstructure distribution. To improve the machining mechanical performance, the greenly grinding generated heat is utilized to generate the coating layer without extra liquid. However, the coating layer microstructure composite is difficult to predict due to the non-steady grinding temperature. A digital complicated microstructure transformation (DCM) model is established and coupled with the transient grinding heat based on the validated improved finite difference method. The austenization, the ferrite reverted transformation, the cementite precipitation, the bainite transformation and the martensite transformation are all considered and automatically distinguished according to the grinding coating CCT. The analytic results indicate that the larger grinding depth mainly increases the bainite content, which can be restricted by improving the feeding rate, and the quicker feeding rate can increase the martensite content by three times. Combined with the measurement of corresponding representative mechanical performances (hardness and the residual stress), the achieved model is verified as an effective tool to realize the microstructure prediction. The research brings about a novelty macro mechanical property control of the grinding coating layer and is significant for achieving higher mechanical performance in surface strengthening manufacturing components. 

Complicated microstructure transformation mechanism of the greenly grinding coating layer

Optimization of process parameters for hardness in high speed coating by Directed Energy Deposition

Investigation on Surface Integrity of Steel DIN 100Cr6 by Grinding Using CBN Tool

Direct Metal Deposition (DMD) for Tooling Repair of DIN 1.2343 Steel

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Investigation on Surface Integrity of Steel DIN 100Cr6 by Grinding Using CBN Tool

Direct Metal Deposition (DMD) for Tooling Repair of DIN 1.2343 Steel