Open Access
Table 3
Comparison of various processes, their basic steps, advantages and limitations.
| Process type | Pre-processing | Post-processing | Advantages | Limitations | Ref |
|---|---|---|---|---|---|
| Electro spark process | Cleaning the workpiece for consistency of the part | A variety of post-processes need to be carried out to ensure dimensional stability | Prevention of liquid metal erosion and burr formation Improved bonding |
No automated applications Liquid metal resistant electrodes required |
[21,51] |
| TGAW, PAW, Brazing, Cladding | Cleaning the part from dirt, grease, etc. Preheating the part to alleviate shrinking, cracking, distortion |
Post heat treatment for stress relaxation Grinding and polishing |
Complex shapes parts repaired Quality parts |
Imperfections in the cooling Heat affected zone Blemish of the repaired part Residual stress |
[52] |
| Metalock process | Cleaning the part from dirt, grease, etc. | Repaired area peened flush and finish | No deformation and stresses Suitable for cast iron Can be used on-site |
Cracked pieces are locked together and not fused to a single material | [21] |
| Robotic laser welding | Same as laser cladding | Non-destructive examination to check the integrity of weld | Dimensionally stable and high accuracy Portable |
Expensive Limited to Nuclear system, Generator repair etc. |
[53–55] |
| Laser cladding, Directed energy deposition (DED) | Cleaning of the material | Machining of excess deposition Shaping of the finished part Finishing shape of the geometry |
Large gaps can be combined Flexible for geometric changes High accuracy High deposition rate Multiple materials deposition Argon purged chamber Small heat-affected zone (HAZ) |
Expensive Integrated approach to get best results Support structure requires for undercuts and overhangs Skilled labour |
[21,22,38,56,57] |
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