Qualification Assessment of High-Value Component Remanufacturing and Repair via Simulation-Based Tools

Qualification Assessment of High-Value Component Remanufacturing and Repair via Simulation-Based Tools | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Qualification Assessment of High-Value Component Remanufacturing and Repair via Simulation-Based Tools Carlos A. Moreira, Michele Chiumenti, Joan Baiges, Henning Venghaus, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-9022449/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 7 You are reading this latest preprint version Abstract Directed Energy Deposition (DED) is increasingly used for the remanufacturing and repair of high-value metallic components, where qualification is often limited by the impracticality of destructive testing and extensive experimental campaigns. In this context, high-fidelity numerical simulations play a critical role in enabling predictive assessment of thermal, mechanical, and solidification phenomena relevant to component integrity. This work investigates the influence of laser power strategies on process stability, thermo-mechanical response, and solidification-driven quality in DED remanufacturing. A conventional constant-power strategy is compared with a modulated-power approach designed to mitigate heat accumulation and stabilize melt-pool behavior. A coupled thermo-mechanical simulation framework based on an embedded-domain formulation is employed, allowing automated handling of complex repair geometries on background meshes. The model captures transient heat transfer, temperature-dependent elasto-viscoplasticity, material deformation, melt-pool morphology, distortion, residual stresses, and solidification-based quality indicators derived from the thermal field. The results show that power modulation substantially improves process stability by maintaining nearly constant melt-pool penetration, area, and volume throughout deposition. Compared with constant power, modulation reduces global warpage and narrows the displacement distribution, while locally increasing residual stresses near the substrate–deposit interface due to enhanced mechanical constraint. Qualification indicators reveal reduced cumulative time above melting, increased cooling rates, and higher thermal gradients under modulated power, indicating more favorable solidification conditions. In contrast, the Niyama criterion shows limited sensitivity among strategies. These findings demonstrate that simulation-driven power modulation enhances geometric accuracy, process stability, and solidification quality in DED remanufacturing. The proposed numerical framework provides a robust, non-destructive basis for qualifying high-value repaired components, supporting informed process optimization where experimental qualification is constrained. Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Under Review Version 1 posted Editorial decision: Revision requested 04 Apr, 2026 Reviews received at journal 03 Apr, 2026 Reviewers agreed at journal 29 Mar, 2026 Reviewers invited by journal 29 Mar, 2026 Editor assigned by journal 29 Mar, 2026 Submission checks completed at journal 04 Mar, 2026 First submitted to journal 03 Mar, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-9022449","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":614215030,"identity":"98268ad2-0efa-4b49-b6a9-1581775945b9","order_by":0,"name":"Carlos A. 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In this context, high-fidelity numerical simulations play a critical role in enabling predictive assessment of thermal, mechanical, and solidification phenomena relevant to component integrity.\nThis work investigates the influence of laser power strategies on process stability, thermo-mechanical response, and solidification-driven quality in DED remanufacturing. A conventional constant-power strategy is compared with a modulated-power approach designed to mitigate heat accumulation and stabilize melt-pool behavior.\nA coupled thermo-mechanical simulation framework based on an embedded-domain formulation is employed, allowing automated handling of complex repair geometries on background meshes. The model captures transient heat transfer, temperature-dependent elasto-viscoplasticity, material deformation, melt-pool morphology, distortion, residual stresses, and solidification-based quality indicators derived from the thermal field.\nThe results show that power modulation substantially improves process stability by maintaining nearly constant melt-pool penetration, area, and volume throughout deposition. Compared with constant power, modulation reduces global warpage and narrows the displacement distribution, while locally increasing residual stresses near the substrate–deposit interface due to enhanced mechanical constraint. Qualification indicators reveal reduced cumulative time above melting, increased cooling rates, and higher thermal gradients under modulated power, indicating more favorable solidification conditions. In contrast, the Niyama criterion shows limited sensitivity among strategies.\nThese findings demonstrate that simulation-driven power modulation enhances geometric accuracy, process stability, and solidification quality in DED remanufacturing. The proposed numerical framework provides a robust, non-destructive basis for qualifying high-value repaired components, supporting informed process optimization where experimental qualification is constrained.","manuscriptTitle":"Qualification Assessment of High-Value Component Remanufacturing and Repair via Simulation-Based Tools","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-04-01 20:17:09","doi":"10.21203/rs.3.rs-9022449/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Revision requested","date":"2026-04-04T13:37:34+00:00","index":"","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2026-04-03T12:44:56+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"50799990244408306050114424387347213661","date":"2026-03-30T02:01:43+00:00","index":"hide","fulltext":""},{"type":"reviewersInvited","content":"","date":"2026-03-30T00:19:08+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2026-03-30T00:17:27+00:00","index":"","fulltext":""},{"type":"checksComplete","content":"","date":"2026-03-04T12:00:53+00:00","index":"","fulltext":""},{"type":"submitted","content":"Engineering with Computers","date":"2026-03-03T16:37:03+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"engineering-with-computers","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"ewco","sideBox":"Learn more about [Engineering with Computers](http://link.springer.com/journal/366)","snPcode":"366","submissionUrl":"https://submission.nature.com/new-submission/366/3","title":"Engineering with Computers","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"021e56d2-3cb6-408f-9e34-3d91fc24552f","owner":[],"postedDate":"April 1st, 2026","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2026-04-22T16:39:25+00:00","versionOfRecord":[],"versionCreatedAt":"2026-04-01 20:17:09","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-9022449","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-9022449","identity":"rs-9022449","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}