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Formation of Super-hard Wear Resistant Coating using Energy Efficient Reactive Laser Additive Manufacturing Technique (REALM)

使用节能反应激光增材制造技术 (REALM) 形成超硬耐磨涂层

基本信息

批准号：
10004433
负责人：
金额：
$ 64.95万
依托单位：
C4 CARBIDES LIMITED
依托单位国家：
英国
项目类别：
Collaborative R&D
财政年份：
2021
资助国家：
英国
起止时间：
2021 至无数据
项目状态：
已结题

来源：
https://gtr.ukri.org/projects?ref=10004433
关键词：
Formation Super hard Wear Resistant

项目摘要

The REALM project will develop a new, sustainable manufacturing technology to produce hard-facings for downhole drilling tools. The proprietary technology uses a novel metal additive manufacturing process based on Directed Energy Deposition (DED) to form highly wear resistant hard-facing coatings in-situ, using elemental powders.The super-hard coating is characterised by a strong metallurgical bond showing a continuous metal-matrix and finely-dispersed carbide precipitates creating functional graded microstructure necessary for wear and erosion applications. This has overcome the drawback encountered when using commercial hard-facing tungsten carbide powders.The project is expected to deliver three innovations:1. Automated, low-heat input manufacturing process to form functionally-graded hard-facings; high toughness at the coating-substrate interface and high hardness on the surface.2. Reactive powder composition formulated using a wide variety of application-targeted material combinations.3. Design freedom of hard-facings to optimise coating geometries for improved heat dissipation and performance.The innovative DED process will benefit the environment; the near-net shape process will lead to more efficient application of tungsten and cobalt thus minimising waste of these expensive at-risk commodities. Localised heating using a laser beam will save energy and greenhouse gases. In service, the downhole tool will exhibit higher performance and will lower energy consumption, whilst its higher longevity will reduce the demand for the primary production of "at-risk" metals.

REALM项目将开发一种新的可持续制造技术，为井下钻井工具生产硬面。该专利技术采用基于定向能量沉积（DED）的新型金属增材制造工艺，使用元素粉末原位形成高耐磨性的硬面涂层。超硬涂层的特点是具有强大的冶金结合力，显示出连续的金属基体和精细分散的碳化物沉淀物，形成磨损和侵蚀应用所需的功能梯度显微组织。该项目克服了使用商用硬质合金粉末时遇到的缺点。该项目预计将带来三项创新：1.自动化、低热输入制造工艺，形成功能梯度的硬面;涂层-基材界面的高韧性和表面的高硬度。2.使用多种应用目标材料组合配制的反应性粉末组合物。硬质合金表面的设计自由度可优化涂层几何形状，从而改善散热和性能。创新的DED工艺将有利于环境;近净形工艺将使钨和钴的应用更有效，从而最大限度地减少这些昂贵的高风险商品的浪费。使用激光束的局部加热将节省能源和温室气体。在使用中，井下工具将表现出更高的性能，并将降低能耗，同时其更长的寿命将减少对“有风险”金属的初级生产的需求。