Criteria for assessing high cycle fatigue (HCF) capability is important for transitioning additive repair technologies to turbine engine applications. By studying the fatigue results of two laser directed energy deposition additive manufacturing repairs on airfoil representative Titanium 6Al-4V coupons, acceptable HCF results for repairs can be determined by observing the confidence in predicted values and the reliability of the empirical data compared to baseline results. The following document details the steps and philosophies behind fabricating coupons that capture the repair capability. Furthermore, regression analysis as well as investigations of dataset distribution, fractography, and microscopy are necessary for instilling confidence in the understanding of repair fatigue behavior. The findings in this work provide a decision gate with quantifiable metrics for advancing novel repair techniques.

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