Numerous technologies are currently available to repair and maintain manufactured metallic parts. However, the real challenge comes when the part has been manufactured to tight tolerances and dimensions, when a relatively small Heat Affected Zone (HAZ) is allowable for the repair, or when the part must perform perfectly in a high reliability application.

Optomec, Inc., in Albuquerque, NM has developed a laser deposition technology commonly known as LENS® (Laser Engineered Net Shaping™), which offers significant advantages over current systems because of its ability to equal or better the properties of conventional wrought metallic materials, and its small HAZ. LENS is also able to add different materials to the part in repair or in newmake, thus potentially offering improved properties in certain locations.

In this paper we will describe applications of LENS in repair of components that are conventionally considered "unrepairable" due to the difficulty of making a repair by conventional means. By drawing on the attributes of the laser deposition method, improved properties, reduced cost, shorter lead times and other benefits may be obtained. Particular attention will be paid to critical aerospace and land-based components.