Abstract
Laser Directed Energy Deposition (LDED) is increasingly utilized for the remanufacturing of high-value components, offering advantages over traditional welding such as lower heat input and the ability to restore complex geometries. Despite these capabilities, the interaction between toolpath strategies, defect removal geometry, and setup accuracy requires further investigation to ensure consistent part quality. This study investigates the influence of groove geometry and deposition strategy on repair outcomes, specifically examining groove angle, contour pass implementation, and contour pass modification type. Additionally, the sensitivity of the repair process to part misalignment relative to groove angle is evaluated to examine process tolerance for setup deviations. These variables are analyzed to determine their combined effect on interfacial bonding efficacy and thermal-mechanical impact on the substrate. The objective is to identify a repair processing window through selection of defect removal geometry and contour passes that optimizes for bonding strength. The findings provide guidelines for tailoring toolpaths to specific geometric constraints and alignment conditions in LDED repair applications.