Repairing surface defects of metal parts by groove machining and wire + arc based filling

Yongzhe Li, Qinglin Han, Imre Horvath, Guangjun Zhang*

*Corresponding author for this work

Research output: Contribution to journalArticleScientificpeer-review

43 Citations (Scopus)
173 Downloads (Pure)


An approach to repairing surface defects of metal parts is proposed, which includes a combined application of (i) groove machining, (ii) wire and arc additive manufacturing (WAAM), and (iii) finishing machining. The completed analysis revealed that (i) the inclination angle of the groove to be machined is strongly influenced by the manufacturing parameters of the WAAM process, and (ii) the WAAM process models designed for fabricating parts on a flat substrate are not appropriate for filling grooves. To overcome these issues, this research investigated the range of variation of the proper inclination angle of the groove. A mathematical model was developed to determine the manufacturing parameters of WAAM that result in a proper filling of the groove. The effectiveness of the proposed fundamentals was investigated in a case study. The experimental results showed that using the proposed approach and the chosen manufacturing parameters resulted in a complete filling of the machined groove. The fabrication error of the main part of the repaired region before the finishing machining was less than 0.3 mm, while the ‘buy-to-fly’ ratio of the deposited material was 92.1%. The proposed approach for morphological repair lends itself to a computer-aided automatic part repair process.

Original languageEnglish
Article number116268
Pages (from-to)1-12
Number of pages12
JournalJournal of Materials Processing Technology
Publication statusPublished - 2019

Bibliographical note

Accepted Author Manuscript


  • Design principles
  • Groove machining
  • Hybrid manufacturing
  • Metal part repair
  • Surface defects
  • Wire and arc additive manufacturing


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