Repairing through Wire Arc Additive Manufacturing: dedicated strategies and sustainability assessment

In the context of circular economy, remanufacturing is gaining attention as a crucial approach to avoid the disposal of worn components by restoring them to their original performance. The aim of this thesis is to develop an effective repair method based on the Wire Arc Additive Manufacturing (WAAM) process for remanufacturing mechanical components, meeting mechanical requirements while reducing costs and environmental impact. This research began with a case study involving the repair of a mold insert using a hybrid WAAM-based process. Several specific repair toolpaths have been developed and evaluated. After the successful restoration of the mold, a sustainability assessment was conducted to compare the benefits of repairing the component versus replacing it with a new one. In addition, a mathematical model was developed to assess the viability of remanufacturing within a supply chain context. This model considers three different supply chains and three types of materials: steel, aluminum, and titanium. The findings indicate that the proposed toolpath strategies significantly improve the WAAM process for repair operations, demonstrating a clear reduction in energy consumption. Closed-loop supply chain analysis outlines the most feasible configurations and conditions under which the remanufacturing approach is viable for mechanical components. In addition, it highlights the most impactful parameters on costs and energy consumption, providing important insights for future research. This study provides valuable insights for industrial applications and contributes to the advancement of sustainable manufacturing practices.