Hybrid manufacturing of complex components: Full methodology including laser metal deposition (LMD) module development, cladding geometry estimation and case study validation

To optimize and satisfy current industrial requirements, during the last decade new alternatives to conventional manufacturing processes are implemented into machines, leading multitasking machines. Especially hybrid machines combining additive subtractive technologies (AM/SM), have become a potential solution for repairing operations in terms of material waste reduction, time consumption flexibility. Nevertheless, this technology has implications machine auxiliary elements as well other challenges: digitalization, process parameterization or CAD/CAM solutions. Thereby, work proposes methodology systems, programmed interface interact between within same environment. The developed application-programming (API) offers CAM module oriented AM with appropriate laser metal deposition (LMD) parameters, three different options strategy programming: Planar LMD, 3-axis LMD 5-axis LMD. Additionally, value stems from implementation an algorithm estimate cladding geometry, so, full resulting geometry can be considered blank SM. A height measuring sensor was obtain real generated clad, critical next machining step. Finally, validate methodology, blisk made Hastelloy®X built-up on Inconel®718 milled final size. Dimensional deviation measured after each process.