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

超高速激光应用（EHLA）是德国Fraunhofer ILT最近（2017年）开发的一种金属涂层工艺。它获得了多个奖项，并获得了重要的工业利益。这引起了提案申请人、TWI及其行业成员（包括英国和海外）的强烈兴趣；EHLA方法现已成为TWI增材制造（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EHLA处理相关的服务、专业知识或工艺开发。为了弥合这一差距，该申请的重点是实现申请人的愿望，并建立和发展一个团队，以指导和承担EHLA过程的工业研究项目——涵盖现有/已知的能力和广泛的未来潜力。该项目将需要4年时间，并将涵盖以下关键方面：采购和集成合适的处理设备，作为EHLA创新的推动者。建立、培训和发展一个专家团队来推动和发展EHLA，调查EHLA在涂料、修复和高速增材制造方面的能力，向TWI工业成员和更广泛的学术和工业界传播案例研究组合。EHLA技术能够以250 cm2/min的最大覆盖率应用每层10 um至300 um厚的金属涂层。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，从而减少了启动基材熔化所需的时间/能量。所得到的涂层质量（>致密99.9%，冶金熔融且无缺陷）可以认为优于热喷涂技术。该工艺也是一种经济且更环保的镀六价铬替代方法。为了实现项目的目标和申请人的愿望，FLF资金将用于建立EHLA设施，并适当地以资源工业为重点的研究和创新。该研究将包括高速涂层、金属添加剂自由成形制造、修复和异种材料连接。该项目将首先建立工艺基础和所得材料特性。当前工业参与和支持的一些预期的、多样化的应用包括：下一代汽车制动盘的六价镀铬替代品，如液压轴和海上部件。硬合金或MMC材料的堆焊涂层，包括闸阀的阀座和阀瓣，阀杆，气缸和工具。用于航空航天和能源应用的圆盘和叶片的修复。ImpactFLF的资金将大大加快英国第一个中心的引进和运营，该中心的重点是为EHLA过程提供工业支持。它还将加速提案人的职业生涯，并使Josh Barras成为全球EHLA技术的领先权威。这种新的颠覆性技术为英国和欧盟市场在许多工业领域带来了巨大的机遇，包括汽车、海上、能源、采矿和钻探以及航空航天。凭借EHLA工艺的技术和经济优势，该技术将创造新的机会，并有望占据硬铬电镀和热喷涂市场的很大比例。EHLA还具有影响和颠覆涂料、修复和增材制造等更广泛市场的潜力。该项目预计将在TWI创造增长，并在技术采用后进入工业公司。在前两年，TWI预计将创造2个新的工作岗位和额外的项目收入100万英镑，在4年内增加到100万英镑，在8年内增加到500万英镑和6个新的工作岗位。

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.