SLIDE 1 Quad City Manufacturing Quad City Manufacturing Laboratory Laboratory Western Illinois University Western Illinois University Additive Manufacturing Laboratory Additive Manufacturing Laboratory
APPLING CERMET (WC) COATINGS VIA INTERNAL
Additive Manufacturing Laboratory Additive Manufacturing Laboratory South South Dakota School of Mines and Technology Dakota School of Mines and Technology
James W Sears
APPLING CERMET (WC) COATINGS VIA INTERNAL BORE LASER CLADDING
James W Sears Director –Additive Manufacturing Laboratory – SDSM&T Exec Director – Quad City Manufacturing Laboratory (QCML)
- Exec. Director Quad City Manufacturing Laboratory (QCML)
David Hotchkiss David Hotchkiss Xaloy, Inc.
SLIDE 2
Acknowledgements Acknowledgements
Joshua Hammell PhD candidate ME SDSM&T Joshua Hammell, PhD candidate, ME, SDSM&T James Tomich, undergraduate, ME, SDSM&T Chris Ludvigson MS-11 ME SDSM&T Chris Ludvigson , MS-11, ME, SDSM&T This work was supported by the Additive Manufacturing This work was supported by the Additive Manufacturing Laboratory (AML) at SDSM&T and under contract to Spirex and then Xaloy to develop Internal Bore Laser p y p Cladding.
SLIDE 3 Outline Outline
- Introduction
- Internal Bore Laser Cladding
- Internal Bore Laser Cladding
- Previous work on WC
- Glass Tooling
- Glass Tooling
- Single Bore (Extrusion)
- T i
B
- Twin Bore
- Cracking Issues
- Results
- Conclusions
SLIDE 4 I t l B L Cl ddi (IBLC) Internal Bore Laser Cladding (IBLC)
South Dakota School of Mines and Technology
SLIDE 5
I t l B L Cl ddi (IBLC) Internal Bore Laser Cladding (IBLC)
SLIDE 6 Current IBLC Capabilities Current IBLC Capabilities
Reach 16in depths Clad a minimum of 2 75in diameter bores Clad a minimum of 2.75in diameter bores Withstand1300°F environment Deliver approximately 2kW to the internal
surface of components surface of components
Deliver 60g/min of powder material Approach surface velocities of 80in/min
South Dakota School of Mines and Technology Hydraulic Cylinder Chrome Replacement
SLIDE 7
Future (4/2012) IBLC at QCML Future (4/2012) IBLC at QCML
3 KW IPG fiber laser 3 axis gantry with coordinated rotary table 3 axis gantry with coordinated rotary table
2’ diameter work area 200 pound load
IBLC head – 2” ID – 20” long Twin 10 powder feeder
SLIDE 8
SLIDE 9 Wear Testing Results (ASTM G65) g ( )
ASTM G65 Abrasion Data
9.00 10.00 m3)
ASTM G65 Abrasion Data
7.00 8.00 me Loss (mm 4 00 5.00 6.00 sted Volum 2.00 3.00 4.00 erage Adjus 0.00 1.00 Ave H d Ch Pl ti NT 60 NT 70 NTC 70SP NTC 70IC Hard Chrome Plating NT-60 NT-70 NTCr-70SP NTCr-70IC
SLIDE 10
Dilution Issues Dilution Issues
Double Layer NiCr-WC Clad
SLIDE 11
WC Reaction with Iron WC Reaction with Iron
SLIDE 12 Source Material Issues Source Material Issues
- Entrapped Gaseous Porosity
pp y
- Size and Distribution
- Fluidity
- Fluidity
- Morphology
- Low Vapor Pressure Elements
- Moisture (affects porosity and fluidity)
( p y y)
SLIDE 13
Cladding Response Cladding Response
SLIDE 14
Cladding Response Cladding Response
SLIDE 15
Cladding Response Cladding Response
SLIDE 16
Cladding Response Cladding Response
SLIDE 17
Glass Forming Tooling Glass Forming Tooling Glass Forming Tooling Glass Forming Tooling
SLIDE 18
Carbide Type (Coarse vs fine) Carbide Type (Coarse vs fine)
SLIDE 19
Carbide Dispersion Carbide Dispersion
Excess Dilution Very Low Dilution
SLIDE 20
Internal Bore Cladding Internal Bore Cladding
SLIDE 21
Internal Bore Laser Cladding Internal Bore Laser Cladding
Internal Bore Laser Cladding (Xaloy)
Application (Plastic Injection Molding Barrels) Application (Plastic Injection Molding Barrels) Improved Performance to extend Barrel Life S l ti
LAM ith 70% WC i NiC SiB M t i
Solution: LAM with 70% WC in NiCrSiB Matrix
SLIDE 22
Single Bore Single Bore
Currently HIP clad with a 70% WC
SLIDE 23
Single Bore Single Bore
SLIDE 24
Single Bore Single Bore
SLIDE 25
Twin Barrels Twin Barrels
SLIDE 26
Twin Barrels Twin Barrels
SLIDE 27
Twin Barrels Twin Barrels
SLIDE 28
Twin Barrels Twin Barrels
SLIDE 29
Twin Barrels Twin Barrels
SLIDE 30 C ki I Cracking Issues
T C k Transverse Crack Transverse Crack Center‐Line Crack Underbead Crack
SLIDE 31
Cracking Issues Cracking Issues
Higher Heat g
SLIDE 32 I i f C k Miti ti Imaging for Crack Mitigation
South Dakota School of Mines and Technology Hydraulic Cylinder Chrome Replacement
SLIDE 33 High Temperature Imaging High Temperature Imaging
South Dakota School of Mines and Technology Hydraulic Cylinder Chrome Replacement
SLIDE 34 C k Miti ti Crack Mitigation
South Dakota School of Mines and Technology
SLIDE 35
Agricultural Applications Agricultural Applications
Combine Harvester: Threshing elements; crop
flow wear target areas; knife and blade edges,
Forage Harvesting: Knife and shear bar edges;
crop flow wear target areas crop flow wear target areas,
Soil tillage tools: Ground engaging elements, Chemical Application: Ground engaging
elements,
Crop Planting: Ground engaging elements, and Conveying of Agricultural materials: Auger edges Conveying of Agricultural materials: Auger edges.
SLIDE 36
Industrial Equipment (a few) Industrial Equipment (a few)
Earth Moving – Wear Coatings Oil & Gas – Hydraulic Cylinders Oil & Gas
Hydraulic Cylinders
Plastics – Extrusion Barrels & Screws Transportation – Wear Surfaces Metal Processing
Tooling Surfaces
Metal Processing – Tooling Surfaces Paper Industry – Saw Blades & Cutters Defense – Wear & Cr Replacement
A L di G
Aerospace – Landing Gear
SLIDE 37 Summary Summary
- Need to understand limitations and specifications
for source powders p
- Must understand Effects of Process Parameters
- n dilution
- n dilution
- NiTung60 should be adequate for Cr repacement
- NiTung70 being proposed for extrusion barrels
- NiTung70 being proposed for extrusion barrels
- Many Industrial Applications for LAM WC MMC’s
- Xaloy with help from QCML and AML is opening
- Xaloy with help from QCML and AML is opening
shop for your applications.
SLIDE 38
