Superalloy Atomisation Trials Using Revert and TurNings (SATURN)

许多制造过程产生的废物处理成本很高，或者不容易回收利用。这一计划是将我们英国客户生产的受污染的金属废料车削和加工副产品转化为高纯度、高价值的镍合金或不锈钢粉末，用于添加剂制造/3D打印和先进应用，包括航空航天和医疗。材料的升级是Liberty/GFG GreenSteel战略的一部分，将原本是废物的材料的价值增加了10倍。由于对新冠状病毒19大流行的影响，社会限制增加了石油和天然气行业现有的压力，因此，预计该部门的投资将长期下滑。因此，除了该行业产生的大量机械加工碎屑外，英国石油和天然气供应链中还有大量部分加工的材料。建议在英国加工车削，以形成一种更易于管理的材料，以帮助处理和熔化我们的250公斤Liberty真空感应熔化(VIM)炉，在开始转换为雾化粉末时使用。建立了有限元模型，模拟了不同比例回转和回转的感应熔炼过程。该模型将指导炉子装炉和熔炼工艺的优化。第一次试验将采集20公斤的转弯样本，一旦证实，将再处理200公斤的负荷，随后将在新委托的Liberty Vim雾化器上进行全面的生产试验。成功的试验将带来巨大的商业机会。

Many manufacturing processes produce waste materials which can be expensive to dispose of or are not readily recycled. This initiative is to take process contaminated metal waste turnings and machining by-products produced by our UK customer and convert them into a high purity, high value nickel alloy or stainless-steel powder for use in additive manufacturing/3D printing advanced applications including aerospace and medical. Upcycling of material is part of the Liberty / GFG Greensteel strategy and increases the value of an otherwise waste material by 10 times.The social restrictions due to the impact on the COVID 19 pandemic has added to the existing strain on the oil and gas industry and as such there is forecast to be a long term downturn in investment in the sector. As a result, there are large quantities of partially processed material within the UK oil and gas supply chain in addition to significant quantities of machining swarf generated in that industry.The proposal is for turnings to be processed in the UK to form a more manageable material to aid handling and melting for use in our 250kg Liberty Vacuum Induction Melting (VIM) furnace at the start of conversion to atomised powder. A finite element model will be developed to simulate induction melting of revert and turnings in various ratio. The model will guide the optimisation of furnace loading and melting process. First trials will take a 20kg sample of turnings and once proven a further 200kg load would be processed followed by full scale production trials on the newly commissioned Liberty VIM atomiser. Successful trial will lead to significant commercial opportunities.