Due to crack occurrence on an unconventionally made insert, produced for high pressure die casting machine, it was necessary to review the literature and analyze possible mechanisms influencing crack initiation, crack propagation, and insert fracture. To determine the main causes of insert failure, I reviewed the literature on the damage mechanisms present in die casting, the occurrence of cracks, mechanical properties due to the SLM fabrication process, and repair welding processes. To ensure a more appropriate repair process, I proposed an improvement to the company, by introducing a hybrid process. The proposed combination of cutting and additive technology DED, could provide a more cost - effective maintenance - repair process.
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