Quad City Manufacturing Quad City Manufacturing Laboratory Laboratory Western Illinois University Western Illinois University Additive Manufacturing Laboratory Additive Manufacturing Laboratory Additive Manufacturing Laboratory Additive Manufacturing Laboratory South Dakota School of Mines and Technology South Dakota School of Mines and Technology APPLING CERMET (WC) COATINGS VIA INTERNAL APPLING CERMET (WC) COATINGS VIA INTERNAL BORE LASER CLADDING James W Sears 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.
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.
Outline Outline Introduction Internal Bore Laser Cladding Internal Bore Laser Cladding Previous work on WC Glass Tooling Glass Tooling Single Bore (Extrusion) T i Twin Bore B Cracking Issues Results Conclusions
I t Internal Bore Laser Cladding (IBLC) l B L Cl ddi (IBLC) South Dakota School of Mines and Technology
I t Internal Bore Laser Cladding (IBLC) l B L Cl ddi (IBLC)
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 Hydraulic Cylinder Chrome Replacement Mines and Technology
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
Wear Testing Results (ASTM G65) g ( ) ASTM G65 Abrasion Data ASTM G65 Abrasion Data 10.00 m3) 9.00 me Loss (mm 8.00 7.00 sted Volum 6.00 5.00 erage Adjus 4.00 4 00 3.00 2.00 Ave 1.00 0.00 H d Ch Hard Chrome Plating Pl ti NT 60 NT-60 NT 70 NT-70 NTC 70SP NTCr-70SP NTC 70IC NTCr-70IC
Dilution Issues Dilution Issues Double Layer NiCr-WC Clad
WC Reaction with Iron WC Reaction with Iron
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 )
Cladding Response Cladding Response
Cladding Response Cladding Response
Cladding Response Cladding Response
Cladding Response Cladding Response
Glass Forming Tooling Glass Forming Tooling Glass Forming Tooling Glass Forming Tooling
Carbide Type (Coarse vs fine) Carbide Type (Coarse vs fine)
Carbide Dispersion Carbide Dispersion Very Low Dilution Excess Dilution
Internal Bore Cladding Internal Bore Cladding
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 Solution: LAM with 70% WC in NiCrSiB Matrix LAM ith 70% WC i NiC SiB M t i
Currently HIP clad with a 70% WC Single Bore Single Bore
Single Bore Single Bore
Single Bore Single Bore
Twin Barrels Twin Barrels
Twin Barrels Twin Barrels
Twin Barrels Twin Barrels
Twin Barrels Twin Barrels
Twin Barrels Twin Barrels
C Cracking Issues ki I T Transverse Crack C k Center ‐ Line Crack Transverse Crack Underbead Crack
Higher Heat Cracking Issues Cracking Issues g
Imaging for Crack Mitigation I i f C k Miti ti South Dakota School of Hydraulic Cylinder Chrome Replacement Mines and Technology
High Temperature Imaging High Temperature Imaging South Dakota School of Hydraulic Cylinder Chrome Replacement Mines and Technology
C Crack Mitigation k Miti ti South Dakota School of Mines and Technology
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.
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 Aerospace – Landing Gear A L di G
Summary Summary Need to understand limitations and specifications for source powders p Must understand Effects of Process Parameters on dilution on 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.
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