Leading innovation and industry uptake of the extreme high-speed laser application (EHLA) process

超高速激光应用 (EHLA) 工艺的领先创新和行业应用

• 批准号: MR/T044365/1
• 负责人: Josh Barras
• 金额: $ 138.96万
• 依托单位: The Welding Institute
• 依托单位国家: 英国
• 项目类别: Fellowship
• 财政年份: 2021
• 资助国家: 英国
• 起止时间: 2021 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=MR%2FT044365%2F1
• 关键词: Leading; innovation; industry; uptake; extreme

The extreme high-speed laser application (EHLA) is a metallic coating process recently developed (2017) in Germany by Fraunhofer ILT. It has received multiple awards and gained significant industrial interest. This has led to strong interest, from the proposal applicant, TWI and its industrial members (both in the UK and overseas); with the EHLA approach now an integral part of TWI additive manufacturing (AM) strategy roadmaps. Currently, there is no capability in the UK to support industry uptake and offer services, expertise or process development in relation to EHLA processing. To bridge this gap, this application is focused on realising the aspirations of the proposer and to building and developing a team to direct and undertake industrial focused research programs on the EHLA process - covering both existing/known capabilities and extensive future potential.The project will require 4 years and will cover the following key aspects: Acquisition and integration of suitable processing equipment as an enabler for EHLA innovation. Build, train and develop an expert team to drive and develop EHLAInvestigate the capability of EHLA for coatings, repair and high-speed additive manufacturing Disseminate a portfolio of case studies to TWI industrial members and the wider academic and industry communities.Technology ConceptThe EHLA technology is capable of applying metallic coatings of 10 um to 300 um thick per layer at a maximum coverage rate of 250 cm2/min. Conventional laser metal deposition coverage rates are 10-40 cm2/min. This is achieved by melting the powder prior to reaching the substrate, thereby reducing the time/energy that would otherwise be needed to invoke melting of the substrate. The resultant quality of coating (>99.9% dense, metallurgically fused and defect free), can be considered superior to that of thermal spray technologies. The process is also an economic and more environmentally friendly alternative approach to hexavalent chromium plating. Project concept To achieve the goals of the project and aspirations of the proposer, FLF funding will enable the setup of an EHLA facility and appropriately, resource industrial focused research and innovation. The research will include high-speed coatings, metal additive freeform manufacturing, repair, and dissimilar material joining. The project will initially establish fundamentals of the process- and resultant material characteristics. Some of the expected, diverse, applications from current industrial engagement and support include:Next generation car brake discs Hexavalent chrome plating replacement, such as hydraulic shafts and offshore components.Hardfacing coatings of hard alloy or MMC materials including, valve seats and discs in gate valves valve stems, cylinders and tooling. Repair of blisks and blades for aerospace and energy applications. ImpactFLF funding will significantly accelerate the introduction and operation of a first UK centre focused on giving industrial support to the EHLA process. It will also accelerate the career profile of the proposer and establish Josh Barras as a leading authority across the globe for the EHLA technology.This new disruptive technology has strong opportunities for UK and EU markets in many industrial sectors including automotive, offshore, energy, mining and drilling, and aerospace. With the technical and economic advantages of the EHLA process, the technology will create new opportunities and is expected to capture a large percentage of hard chrome plating and thermal spray markets. EHLA also has the potential to influence and disrupt a wider number of markets across coatings, repair, and additive manufacturing. The project is expected to create growth at TWI and into industrial companies following technology uptake. Within the first two years, TWI expects to create 2 new jobs and additional project income of >£1M, increasing to >£3M within 4 years, and >£5M and 6 new jobs within 8 years.

超高速激光应用(EHL)是Fraunhofer ILT最近(2017年)在德国开发的一种金属涂层工艺。它获得了多个奖项，并获得了巨大的行业兴趣。这引起了提案申请人TWI及其行业成员(英国和海外)的浓厚兴趣；EHL方法现已成为TWI添加剂制造(AM)战略路线图的组成部分。目前，英国没有能力支持行业吸收并提供与EHL处理相关的服务、专业知识或过程开发。为了弥补这一差距，这项申请专注于实现建议者的愿望，并建立和发展一支团队，指导和承担关于EHL过程的以工业为重点的研究计划-涵盖现有/已知的能力和广泛的未来潜力。该项目将需要4年，将涵盖以下关键方面：采购和集成合适的处理设备，作为EHL创新的推动者。建立、培训和开发一支专家团队，以推动和开发EHLA研究EHL在涂层、修复和高速添加剂制造方面的能力向TWI行业成员和更广泛的学术和行业社区传播一系列案例研究。技术概念EHL技术能够在每层10微米至300微米厚的金属涂层上涂覆，最大覆盖率为250 cm2/min。传统的激光金属沉积覆盖率为10-40 cm2/min。这是通过在到达基材之前熔化粉末来实现的，从而减少了否则需要熔化基材所需的时间/能量。由此产生的涂层质量(99.9%致密、冶金熔合且无缺陷)可被认为优于热喷涂技术。该工艺也是六价铬电镀的一种经济和更环保的替代方法。项目概念为了实现项目的目标和提出者的愿望，FLF的资金将使EHL设施的建立和适当的、以工业为重点的研究和创新成为可能。这项研究将包括高速涂层、金属添加剂自由形式制造、修复和不同材料的连接。该项目将初步确立该工艺的基本原理--以及由此产生的材料特性。当前工业参与和支持的一些预期的、多样化的应用包括：下一代汽车制动盘六价铬电镀替代品，如液压轴和离岸部件。硬质合金或MMC材料的硬面涂层，包括闸阀中的阀座和阀片、阀杆、气缸和工具。航空航天和能源应用的叶盘和叶片的维修。ImpactFLF的资金将大大加快英国第一个中心的引入和运营，该中心专注于为EHL进程提供工业支持。它还将加速提出者的职业形象，并将Josh Barras确立为全球EHL技术的领先权威。这项新的颠覆性技术在包括汽车、海上、能源、采矿和钻探以及航空航天在内的许多工业部门为英国和欧盟市场带来了巨大的机遇。凭借EHL工艺的技术和经济优势，该技术将创造新的机会，预计将占领很大比例的硬铬电镀和热喷涂市场。EHL还有可能影响和颠覆涂料、修复和添加剂制造等更广泛的市场。该项目预计将在TWI创造增长，并在采用技术后进入工业公司。在头两年内，TWI预计将创造2个新的工作岗位和额外的项目收入&gt；100万GB，在4年内增加到&gt；300万，在8年内增加到&gt；500万和6个新的工作岗位。