Development of resource efficient manufacturing process to produce sustainable hardmetal powders for laser Directed Energy Deposition

在部件表面应用堆焊涂层是一种常见的工业工艺，用于提高耐磨性、耐热性和耐腐蚀性。典型的硬面加工工艺，包括热喷涂和电镀，以及最近的激光定向能沉积(DED)。拟议的项目将开发一种新的、资源高效的硬质合金粉末制造技术和相关的硬质合金粉末，专门为DED设计。这个为期6个月的项目将从传统的硬质合金粉末制造中消除浪费和昂贵的制造阶段。通过将新材料和DED结合到涂层制造方法中，可以克服与硬质合金脱碳、涂层寿命、工艺成本效益、新材料解决方案的快速设计和测试有关的重大障碍和限制。项目成果在专注于DED硬面的同时，可以应用于其他需要高耐磨性和低摩擦的添加剂制造和粉末冶金工艺，用于一次制造和维修。该项目的成功将为硬面行业提供颠覆性的解决方案，并推动数十亿英镑的MRO行业走向更绿色和可持续的涂层。

The application of a hardfacing coating to the surface of a component is a common industrial process used to enhance wear, thermal and corrosion resistance. Typical hardfacings processes including thermal spraying and electroplating, and more recently Laser Directed Energy Deposition (DED).The proposed project will develop a new, resource efficient hardmetal powder manufacturing technology and associated hardmetal powders, designed specifically for DED. The 6-months project will remove wasteful and expensive manufacturing stages from conventional hardmetal powder manufacturing. By combining the new materials and DED into a coating manufacturing methodology, significant hurdles and limitations related to carbide decarburisation, coating life, process cost effectiveness, rapid design and testing of new material solutions can be overcome.The project outcomes, while focusing on the DED hardfacings, can be applied to other additive manufacturing and powder metallurgy processes that require high wear resistance and low friction, for both primary manufacturing and repairs. Success in the project will provide disruptive solutions for the hardfacings community and drive the multi-billion-pound MRO sector towards greener and sustainable coatings.