Innovations in repair and fabrication of cutting tools using automated laser cladding

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The price of tungsten has gone up by about 300% since 2004 (The Economist, April 14th 2005). This increase in price is expected to continue due to a huge demand from developing countries (China alone uses more than 30% of world tungsten production) and the lack of  new opencast mines discoveries in the world. Good quality WC tools are usually used for 400 cutting tasks before they need to be resharpened. The number of resharpening steps depends on the features of the tools and it is very limited for special tools built for machining of high volume parts. After the maximum number of resharpening, the tool is scrapped although a few millimeters addition to its length can save $300-$400 worth of tool. In many cases a cutting tool is scrapped because of small manufacturing errors or the presence of small chips.   In this project, laser cladding is used to develop a new technique to repair WC cutting tools. In addition, cladding of tungsten-carbide on non-WC substrates such as alloy steel will be studied to develop new low-cost steel tools with WC cutting edges. Furthermore, fabrication of diamond and cermet tools using laser cladding will be investigated. The applicants state of the art lab facilities which include a 1000 W ND:YAG laser, powder feeders, 4-axis positioning table, and vision system for monitoring and control of  the clad will be utilized in the project. The requested funding will primarily be used to support graduate students and one post-doctoral fellow.