Development of advanced surfaces using laser technologies for better performance at lower cost
Laser additive manufacturing technologies offer a wide spectrum of opportunities to provide metallic components with advanced characteristics against corrosion and wear by adding ad-hoc coatings. However, iron casting presents important limitations regarding this technology that jeopardize the integrity of the components: generation of heterogeneous thermal and stress zones, porosity, hardened and brittle phases, etc. that directly affect the mechanical properties of the castings.
To overcome this limitation and enable the application of laser technologies on the surface of cast iron components, AZTERLAN has developed an innovative methodology (protected by patent) that includes several developments: a reactive paint that allows the surface of the component to be conditioned from its demolding, the manufacturing process of a disposable mold with special characteristics and the part with advanced properties resulting from the process.
Conditioning element based on an ad-hoc developed and ad-hoc atomized metallic alloy and an inorganic binder (aqueous sodium silicate solution).
Applied in the cavity of the mold, this product behaves as a ‘primer’, leaving the surface of the part ready for the application of LMD from its demoulding.
Disposable sand mold treated with reactive paint in the zones of the cavity corresponding to the areas of the castings aimed to coat by means of LMD.
The mold is totally or partially moistened before the reactive paint is applied to regulate the absorption of this element and ensure its transfer to the surface of the part.
From its demolding, the part is ready for the subsequent safe application of coatings by means of LMD technologies.
However, from its as-cast state, the part presents better corrosion and wear properties than a cast iron that has not been treated.
Separation of the mechanical function of the interior of the piece and the function of resistance to environmental attack on the outside of the component.
Substitution of solid components currently made of high-priced alloys, with a body of conventional material (substrate) and a high-value skin (coating).
Freedom of selection of the reacted surfaces and wide spectrum of applicable coating materials.
Homogeneous and continuous distribution of the reacted layer.
«Our work is aimed at mastering the physics and the chemistry that govern the behavior of metallic alloys, the phenomena that take place during manufacturing processes and the conditions that affect the useful life of metallic components.
We rethink metallurgy to develop more effective, efficient and sustainable manufacturing processes that favor the manufacture of components with enhanced properties and that open up new fields of application».
