The repair and remanufacturing process of aero-engine blades requires high geometric accuracy and mechanical properties. Therefore, the synergy of multiple processes is required to complete the repair of blades. This paper mainly studies the coupling relationship between multiple processes of aero-engine blade repair and the influence and role of each process on the final surface integrity of the blade. First, in response to the needs of blade repair, a hybrid remanufacturing process chain of laser cladding, CNC machining and ultrasonic rolling is proposed. Then, a numerical model of geometric feature construction and transient thermal-structural behavior in the hybrid remanufacturing process chain of blades is established.

Finally, the mutual influence between the three processes of laser cladding, CNC machining and ultrasonic rolling is analyzed. The results show that a larger powder feeding rate is allowed during the laser cladding process of the hybrid remanufacturing process chain of blades. The thermal deformation and residual stress caused by high powder feeding rate and thin wall structure can be optimized by CNC machining and ultrasonic rolling. In addition, the influence mechanism of the three processes on the final surface integrity is revealed, and it is shown that the influence of hybrid remanufacturing process parameters on remanufacturing quality is different from that of traditional processes. The feasibility of the hybrid remanufacturing process chain for blades was demonstrated through verification experiments on damaged blades.