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

将堆焊涂层应用于组件表面是一种常见的工业过程，用于增强耐磨性，耐热性和耐腐蚀性。典型的堆焊工艺包括热喷涂和电镀，以及最近的激光定向能沉积（DED）。该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个月的项目将消除传统硬质合金粉末制造中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，可以克服与碳化物脱碳、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相关的重大障碍和限制。该项目的成果，虽然侧重于DED堆焊，但可以应用于其他需要高耐磨性和低摩擦的增材制造和粉末冶金工艺，用于初级制造和维修。该项目的成功将为硬表面处理行业提供颠覆性的解决方案，并推动价值数十亿英镑的MRO行业向更环保和可持续的涂料发展。

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.