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

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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.