Torque loss characterization of an FZG-C Type C-GF gear rebuilt via Direct Laser Deposition

Torque loss characterization of an FZG-C Type C-GF gear rebuilt via Direct Laser Deposition | 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 Torque loss characterization of an FZG-C Type C-GF gear rebuilt via Direct Laser Deposition Pedro Romio, Pedro M. T. Marques, Carlos M. C. G. Fernandes, Jorge H. O. Seabra This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8428757/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 12 Mar, 2026 Read the published version in Progress in Additive Manufacturing → Version 1 posted You are reading this latest preprint version Abstract Direct Laser Deposition (DLD) is a metal additive manufacturing process that can potentially extend the useful life of gears. The DLD repair process proved to be applicable in several cases. However, concrete applications of DLD for gears are still limited to teeth reconstruction without considering functional applications. This research evaluates the torque loss of an FZG-C Type C-GF gear rebuilt using DLD under actual operation. The study details the strategy used to restore a case-hardened 16MnCr5 FZG-C Type C-GF gear with a combination of Inconel 625 for the tooth core and AISI 431 as a superficial coating, and it compares its performance with a base material pinion (not repaired). This work extends the analysis performed in a previous attempt and presents a much more comprehensive characterisation. The results include visual inspection, base tangent length assessment, double-flank working test, torque loss and microhardness measurements. The DLD teeth showed very good adhesion to the base material during the tests and similar torque loss behaviour to the reference. Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Published Journal Publication published 12 Mar, 2026 Read the published version in Progress in Additive Manufacturing → Version 1 posted 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-8428757","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":565768359,"identity":"3d42aaca-5684-489c-879f-de493018eff6","order_by":0,"name":"Pedro Romio","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAArElEQVRIiWNgGAWjYHACxgcJIIqZBC3MBkhaDIjSwiaBxCFCi3l7d1rFgz82eQzsvMceMO74Q1iLzJmz224ktqUVMzDzpRswniHCFgmJXKCWhsOJDcw8ZhKMbURqKUj4859ELQwJbAdI0cJzdrNEYltyMRvIL4lnjInQwt678eOPP3Z5/Pxnjz34uEOOsBYYSGBj4GFjSGwgXgdDAgNICyMpWkbBKBgFo2DEAABxvDJ7r0Pc0QAAAABJRU5ErkJggg==","orcid":"","institution":"Polytechnic Institute of Porto","correspondingAuthor":true,"prefix":"","firstName":"Pedro","middleName":"","lastName":"Romio","suffix":""},{"id":565768360,"identity":"e19db522-cca1-4ca6-9cbc-80dfe26bdd30","order_by":1,"name":"Pedro M. T. Marques","email":"","orcid":"","institution":"University of Porto","correspondingAuthor":false,"prefix":"","firstName":"Pedro","middleName":"M. T.","lastName":"Marques","suffix":""},{"id":565768361,"identity":"87180e44-08d1-477a-863a-87eafa9ee6fd","order_by":2,"name":"Carlos M. C. G. Fernandes","email":"","orcid":"","institution":"University of Porto","correspondingAuthor":false,"prefix":"","firstName":"Carlos","middleName":"M. C. G.","lastName":"Fernandes","suffix":""},{"id":565768362,"identity":"2394903d-762c-4072-a0f5-2d0d3b07498e","order_by":3,"name":"Jorge H. O. Seabra","email":"","orcid":"","institution":"University of Porto","correspondingAuthor":false,"prefix":"","firstName":"Jorge","middleName":"H. O.","lastName":"Seabra","suffix":""}],"badges":[],"createdAt":"2025-12-22 23:53:17","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-8428757/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-8428757/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s40964-026-01586-y","type":"published","date":"2026-03-12T15:57:48+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":99317779,"identity":"b2a0bb74-c1d2-4e19-ba5c-e404b1272950","added_by":"auto","created_at":"2025-12-31 16:30:42","extension":"docx","order_by":0,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":12719901,"visible":true,"origin":"","legend":"","description":"","filename":"TorquelosscharacterizationofanFZGCTypeCGFgearrebuiltviaDirectLaserDepositionFinal.docx","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/265bcc999953f86f3f4f457b.docx"},{"id":99227391,"identity":"1257eb7e-c67a-4c44-a99d-78cefa0da080","added_by":"auto","created_at":"2025-12-30 10:56:23","extension":"json","order_by":1,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":5484,"visible":true,"origin":"","legend":"","description":"","filename":"03566ddf014e4bdf9d32e63eb644f005.json","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/83200912927a0b867ceac68a.json"},{"id":99318255,"identity":"267bb080-660b-434d-8118-e8c5daf07a20","added_by":"auto","created_at":"2025-12-31 16:32:25","extension":"xml","order_by":2,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":111806,"visible":true,"origin":"","legend":"","description":"","filename":"03566ddf014e4bdf9d32e63eb644f0051enriched.xml","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/73f59bc14c9c5c8bfa2ce3e1.xml"},{"id":99317712,"identity":"28e737f7-e5c9-45e9-b7a7-d258d7f30b72","added_by":"auto","created_at":"2025-12-31 16:30:37","extension":"emf","order_by":3,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":580840,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage1.emf","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/295ca6e4ada6a2a940da585f.emf"},{"id":99317744,"identity":"07544d5a-e149-4f11-9c09-2ae54b1fc4ca","added_by":"auto","created_at":"2025-12-31 16:30:40","extension":"emf","order_by":4,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":21936,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage10.emf","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/fcaff938c93b28107d7c2888.emf"},{"id":99318827,"identity":"9c7c25fd-505d-4170-a07c-110b8dcf53f0","added_by":"auto","created_at":"2025-12-31 16:35:05","extension":"jpeg","order_by":5,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":55591,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage11.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/1bdf67dfb17675a2385b8d1e.jpeg"},{"id":99317630,"identity":"e4e3e6be-40ea-4cb5-8769-48a0b0849864","added_by":"auto","created_at":"2025-12-31 16:30:30","extension":"jpeg","order_by":6,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":132976,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage12.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/359c3cf9ada6634e1e3a933b.jpeg"},{"id":99319033,"identity":"6344a348-2559-4cb3-911d-9e2670b5d7e5","added_by":"auto","created_at":"2025-12-31 16:36:06","extension":"jpeg","order_by":7,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":190349,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage13.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/0e982986d4cefc8c76538e43.jpeg"},{"id":99227394,"identity":"a5781bba-7919-4459-8144-bb93b524528c","added_by":"auto","created_at":"2025-12-30 10:56:23","extension":"jpeg","order_by":8,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":179683,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage14.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/931c9a12c55b0a685bb502c7.jpeg"},{"id":99227397,"identity":"aad7cd9a-238a-4d0a-b86d-8f5454d8ba1c","added_by":"auto","created_at":"2025-12-30 10:56:23","extension":"jpeg","order_by":9,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":182252,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage15.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/289391836c7d77325df88ec7.jpeg"},{"id":99227426,"identity":"5ab0c3e4-f4ef-4b45-8e75-4915fa1f108b","added_by":"auto","created_at":"2025-12-30 10:56:26","extension":"emf","order_by":10,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":233588,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage16.emf","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/4a5e999305984b2698c3e12b.emf"},{"id":99318188,"identity":"58af052e-be51-4411-800d-533e96ddcf39","added_by":"auto","created_at":"2025-12-31 16:31:51","extension":"jpeg","order_by":11,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":243676,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage2.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/c9c597e9fd1ee49890d3dfb2.jpeg"},{"id":99227398,"identity":"c62524e5-a1cb-4865-bf8a-44af25e72969","added_by":"auto","created_at":"2025-12-30 10:56:23","extension":"png","order_by":12,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":68057,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage3.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/2ce752063f059018e4c3abca.png"},{"id":99227404,"identity":"6efa48bb-ff3a-43c7-bb09-1317e5bb146a","added_by":"auto","created_at":"2025-12-30 10:56:23","extension":"emf","order_by":13,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":876536,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage4.emf","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/6b88aa1f5aa0f0a93fe07942.emf"},{"id":99227405,"identity":"51eea4dd-ae2f-4285-971a-887ebe3f2f96","added_by":"auto","created_at":"2025-12-30 10:56:23","extension":"emf","order_by":14,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":41836,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage5.emf","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/370f7d5ce102f26d8f59b0a7.emf"},{"id":99227406,"identity":"eb940cbf-0732-4c3a-a98a-4d97191ddaa3","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"jpeg","order_by":15,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":214547,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage6.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/2db392ab7afb61805838f165.jpeg"},{"id":99227402,"identity":"7d797e4e-a0c4-4511-a0ee-b8140ef7f10d","added_by":"auto","created_at":"2025-12-30 10:56:23","extension":"jpeg","order_by":16,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":965534,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage7.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/923794284617c1be56d4032a.jpeg"},{"id":99227416,"identity":"54dbb0af-4c85-452a-abc9-aa04d4642d69","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"emf","order_by":17,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":293112,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage8.emf","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/1c978a502137847b44216664.emf"},{"id":99227420,"identity":"fb6c546b-eef0-4ab1-9c99-d1600193cf7c","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"jpeg","order_by":18,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":986485,"visible":true,"origin":"","legend":"","description":"","filename":"floatimage9.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/66ef7331e8a01a3d98b886b1.jpeg"},{"id":99227412,"identity":"15058af5-6204-4030-b204-c361a8c57e4e","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"png","order_by":19,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":132940,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage1.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/8cac3fdd5a3459b0f306497d.png"},{"id":99317977,"identity":"3bd932aa-2b15-4348-90c6-deddbcbec040","added_by":"auto","created_at":"2025-12-31 16:31:04","extension":"png","order_by":20,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":50713,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage10.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/accd425d7cf2239f408fb38c.png"},{"id":99227400,"identity":"fa7f73e9-851a-4434-bce9-19554ef53f86","added_by":"auto","created_at":"2025-12-30 10:56:23","extension":"png","order_by":21,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":10997,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage11.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/74856994ba9f18ea25294ed2.png"},{"id":99227409,"identity":"72792b49-b46d-40f4-9a44-610f5ed78133","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"png","order_by":22,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":31174,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage12.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/01f99c348e30e9116148d7b3.png"},{"id":99227424,"identity":"5772eb9b-f9b9-494b-8d64-ca194516faba","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"png","order_by":23,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":32816,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage13.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/2d9005c737a9e02f8dd04192.png"},{"id":99227408,"identity":"c008f1ab-131f-4639-90d5-4688c085275a","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"png","order_by":24,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":30839,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage14.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/2f179a4dfcad9675b8c422d5.png"},{"id":99227410,"identity":"623309e8-e6bd-47d6-be57-e027192da6fa","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"png","order_by":25,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":30940,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage15.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/35455aa24e8a72e9b9716a4d.png"},{"id":99227407,"identity":"e5a03c9a-fe0c-466d-9796-598b26ab1b0e","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"png","order_by":26,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":85684,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage16.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/31a9d755699a3ca1ab34acbe.png"},{"id":99319282,"identity":"0487bfba-9db6-45c9-a18a-f866d381ab13","added_by":"auto","created_at":"2025-12-31 16:36:49","extension":"png","order_by":27,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":176537,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage2.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/c51a1303b1cb6a008c2e09b1.png"},{"id":99320469,"identity":"8496342d-8706-4a7b-bf2d-9851dce29a2d","added_by":"auto","created_at":"2025-12-31 16:38:38","extension":"png","order_by":28,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":21535,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage3.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/92a3cdba25d763e3b2a8caa7.png"},{"id":99319344,"identity":"68ce6c36-b7e3-47ed-b1ff-7785172a1d3d","added_by":"auto","created_at":"2025-12-31 16:36:59","extension":"png","order_by":29,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":220313,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage4.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/bf5dc41cf0911e3177c6aef4.png"},{"id":99317774,"identity":"7b5a9f9e-5d67-4968-884d-821f092c9ac1","added_by":"auto","created_at":"2025-12-31 16:30:42","extension":"png","order_by":30,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":174225,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage5.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/82651dd948cfb6dfafe93eff.png"},{"id":99227419,"identity":"814d6fa7-d430-49ab-85e1-0be49ab91985","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"png","order_by":31,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":77193,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage6.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/469f7b987991e4803fcaceab.png"},{"id":99227423,"identity":"662703b8-f6e5-4e81-9e08-75d6b88a65c2","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"png","order_by":32,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":360557,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage7.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/9d2f9c123048e4c502b55754.png"},{"id":99319263,"identity":"b2a532f5-5e1d-4420-9aac-eeea1b5ae528","added_by":"auto","created_at":"2025-12-31 16:36:46","extension":"png","order_by":33,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":972305,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage8.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/a7822632aca70becd8bb4cd8.png"},{"id":99227428,"identity":"6fc16ca4-f3f4-4b6d-83fd-a065c31ed3ad","added_by":"auto","created_at":"2025-12-30 10:56:27","extension":"png","order_by":34,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":277378,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage9.png","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/f73a2b3a1e338e5508c787f5.png"},{"id":99317995,"identity":"0c586ffe-f038-474c-95bb-158ecf80a47d","added_by":"auto","created_at":"2025-12-31 16:31:07","extension":"xml","order_by":35,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":110959,"visible":true,"origin":"","legend":"","description":"","filename":"03566ddf014e4bdf9d32e63eb644f0051structuring.xml","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/66e029e7cc66dceb0b9caf7c.xml"},{"id":99227417,"identity":"164e451d-3b26-4533-aab5-10596d514525","added_by":"auto","created_at":"2025-12-30 10:56:24","extension":"html","order_by":36,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":126675,"visible":true,"origin":"","legend":"","description":"","filename":"earlyproof.html","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1/ae3f6f51e3c7c32c116bb6df.html"},{"id":104740455,"identity":"2a69df32-bc26-49c3-a386-83894c6f311e","added_by":"auto","created_at":"2026-03-16 16:18:15","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1547333,"visible":true,"origin":"","legend":"","description":"","filename":"TorquelosscharacterizationofanFZGCTypeCGFgearrebuiltviaDirectLaserDepositionFinal.pdf","url":"https://assets-eu.researchsquare.com/files/rs-8428757/v1_covered_bffdf8f5-b9b8-4a0b-88e4-478e29a7709a.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Torque loss characterization of an FZG-C Type C-GF gear rebuilt via Direct Laser Deposition","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"","lastPublishedDoi":"10.21203/rs.3.rs-8428757/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8428757/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eDirect Laser Deposition (DLD) is a metal additive manufacturing process that can potentially extend the useful life of gears. The DLD repair process proved to be applicable in several cases. However, concrete applications of DLD for gears are still limited to teeth reconstruction without considering functional applications. This research evaluates the torque loss of an FZG-C Type C-GF gear rebuilt using DLD under actual operation. The study details the strategy used to restore a case-hardened 16MnCr5 FZG-C Type C-GF gear with a combination of Inconel 625 for the tooth core and AISI 431 as a superficial coating, and it compares its performance with a base material pinion (not repaired). This work extends the analysis performed in a previous attempt and presents a much more comprehensive characterisation. The results include visual inspection, base tangent length assessment, double-flank working test, torque loss and microhardness measurements. The DLD teeth showed very good adhesion to the base material during the tests and similar torque loss behaviour to the reference.\u003c/p\u003e","manuscriptTitle":"Torque loss characterization of an FZG-C Type C-GF gear rebuilt via Direct Laser Deposition","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-12-30 10:56:18","doi":"10.21203/rs.3.rs-8428757/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"704256d9-3a3c-4733-bf51-d3e04e439b73","owner":[],"postedDate":"December 30th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2026-03-16T16:15:00+00:00","versionOfRecord":{"articleIdentity":"rs-8428757","link":"https://doi.org/10.1007/s40964-026-01586-y","journal":{"identity":"progress-in-additive-manufacturing","isVorOnly":false,"title":"Progress in Additive Manufacturing"},"publishedOn":"2026-03-12 15:57:48","publishedOnDateReadable":"March 12th, 2026"},"versionCreatedAt":"2025-12-30 10:56:18","video":"","vorDoi":"10.1007/s40964-026-01586-y","vorDoiUrl":"https://doi.org/10.1007/s40964-026-01586-y","workflowStages":[]},"version":"v1","identity":"rs-8428757","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8428757","identity":"rs-8428757","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}