ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 22 The mining industry has perpetually demanded robust, high-performing tools capable of enduring the harsh conditions of mineral extraction[1]. Traditionally, mining tools have been manufactured through conventional methods that entail intricate machining, casting, and welding processes. However, these techniques often exhibit limitations in terms of design complexity, material versatility, and cost-effectiveness[2]. The advent of additive manufacturing technologies has ushered in a transformative era for manufacturing mining tools, promising unprecedented agility, precision, and efficiency. BENEFITS OF ADDITIVE MANUFACTURING IN MINING TOOLS Additive manufacturing techniques, encompassing processes like selective laser melting (SLM), electron beam melting (EBM), and laser metal deposition (LMD), offer a multitude of advantages for mining tools production[2]. First, these techniques facilitate intricate geometric designs that were hitherto challenging or unfeasible with traditional methods. This affords the capability to tailor tools for specific mining conditions, optimizing performance[3]. Second, additive manufacturing enables the consolidation of multiple components into a single, integrated structure, reducing assembly complexity and potential points of failure. Furthermore, the layer-by-layer nature of additive manufacturing minimizes material waste, contributing to cost-efficiency and sustainability. CHALLENGES AND CONSIDERATIONS While additive manufacturing holds immense promise, its integration into manufacturing mining tools necessitates a thorough acknowledgment of challenges[4]. A primary concern is the demand for skilled labor adept at both mining engineering and additive manufacturing principles. Adequate training and education are imperative to bridge this knowledge gap. Moreover, appropriate material selection is pivotal to ensure optimal tool functionality, encompassing factors like wear resistance[5], heat tolerance, and corrosion resilience. Rigorous quality- control measures are paramount to certify the structural integrity and reliability of additively manufactured tools, thus necessitating the development of robust inspection and testing protocols. CASE STUDY A case study explores the successful utilization of WC-NiCrBSi mixed powder as a protective coating on AISI 9310 steel components within the context of mining-tool manufacturing. The aim was to enhance wear resistance and ADDITIVELY MANUFACTURING MINING TOOLS Additive manufacturing techniques give the mining industry a chance to revolutionize the conceptualization, prototyping, and production of mining tools, including using WC-Fe, Ni-based matrix coatings that display exceptional properties. Varun Kumar Kurapati OP Jindal University, India Fig. 1 – Schematic of laser metal deposition. durability, ultimately prolonging the operational lifespan of these critical mining tool elements. AISI 9310 steel, chosen for its robust mechanical properties, was employed in its nonheat-treated state to evaluate the effectiveness of the additive manufacturing coating independently from any heat treatment benefits. The process, as illustrated in Fig. 1, involved a meticulous sequence of steps[2]. A custom Python program was developed to orchestrate the additive manufacturing machine’s operations. Upon initiation, the machine triggered the flow of shielding gas through the powder feeder and nozzle. The nozzle, intricately designed, featured an aperture along with three strategically positioned vent holes. This design not only facilitated the controlled dispersion of the WC-NiCrBSi
RkJQdWJsaXNoZXIy MTYyMzk3NQ==