Critical metallic components such as jet engine turbine blades and casting die/mold may be damaged after servicing for a period at harsh working environments such as elevated temperature and pressure, impact with foreign objects, wear, corrosion, and fatigue. Additive manufacturing has a promising application for the refurbishment of such high-costly parts by depositing materials at the damaged zone to restore the nominal geometry. However, several issues such as pre-processing of worn parts to assure the repairability, reconstructing the repair volume to generate a repair tool path for material deposition, and inspection of repaired parts are challenging. The current research aims to address crucial issues associated with component repair based on three research topics. The first topic is focusing on the development of pre-repair processing strategies which includes pre-repair machining to guarantee the damaged parts are ready for material deposition and pre-repair heat-treatment to restore the nominal mechanical properties. For this purpose, some damaged parts with varied defects were processed based on the proposed strategies. The second topic presents algorithms for obtaining the repair volume on damaged parts by comparing the damaged 3D models with the nominal models. Titanium compressor blades and die/mold were used as case studies to illustrate the damage detection and reconstructing algorithms. The third topic is the evaluation of repaired components through material inspection and mechanical testing to make sure the repair is successful. The current research contributes to metallic component remanufacturing by providing knowledge to solve key issues coupled with repair. Moreover, the research results could benefit a wide range of industries, such as aerospace, automotive, biomedical, and die casting --Abstract, page iv
