Doctoral Dissertations

Keywords and Phrases

3D printing; Additive manufacturing; Component repair; Damage reconstruction; Laser metal deposition; Material characterization


"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.


Liou, Frank W.

Committee Member(s)

Midha, A. (Ashok)
Chandrashekhara, K.
Pan, Heng
He, Xiaoming


Mechanical and Aerospace Engineering

Degree Name

Ph. D. in Mechanical Engineering


Projects were supported by NSF Grants CMMI-1547042 and CMMI 1625736; TOYOTA/Bodine Aluminum; the Center for Aerospace Manufacturing Technologies, and Material Research Center at Missouri S&T; the Center for Energy Technology and Strategy, National Cheng Kung University; and National Chung-Shan Institute of Science & Technology. The research and dissertation were also supported by Laser-Aided Manufacturing Processes (LAMP) Laboratory and Intelligent Systems Center (ISC) at the Missouri University of Science and Technology.

Research Center/Lab(s)

Intelligent Systems Center


Missouri University of Science and Technology

Publication Date

Fall 2019

Journal article titles appearing in thesis/dissertation

  • Experimental characterization of a direct metal deposited cobalt-based alloy on tool steel for component repair
  • Development of pre-repair processing strategies for laser-aided metallic component remanufacturing
  • Damage detection and reconstruction algorithm in repairing compressor blade by direct metal deposition
  • Damage reconstruction from tri-dexel data for laser-aided repairing of metallic components
  • Evaluation of component repair using direct metal deposition from scanned data


xvi, 160 pages

Note about bibliography

Includes bibliographic references.


© 2019 Xinchang Zhang, All rights reserved.

Document Type

Dissertation - Open Access

File Type




Thesis Number

T 11659

Electronic OCLC #