ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 23 TABLE 1 — MICRO HARDNESS FROM THE INTERFACE IN THE HAZ REGION Depth, mm 0.1 0.3 0.5 0.7 0.9 1.1 1.3 1.5 HV 0.5 515 495 455 400 355 325 320 320 mixed powder but also allowed for effective cooling of the copper nozzle, preventing overheating during the deposition process[6]. To closely monitor the additive manufacturing process and ensure quality control, an infrared camera was integrated[2]. This infrared monitoring provided real-time visualization of the deposition process, enabling operators to assess layer integrity and detect potential anomalies. Additionally, a pyrometer was used to gauge the temperature of the laser, ensuring precise temperature management throughout the additive manufacturing process[6]. The synergy of these technological components created an integrated system that enabled accurate and controlled deposition of the WC-NiCrBSi mixed powder and also facilitated real-time quality assessment and process optimization. This case study exemplifies the successful implementation of advanced additive manufacturing techniques in the mining tools industry, illustrating the potential of innovative coatings to significantly enhance wear resistance and durability. The careful orchestration of process parameters, coupled with real-time monitoring and control, underlines the transformative impact of additive manufacturing on traditional mining tool production paradigms. As industries continue to embrace digital innovation, the integration of cutting- edge technologies such as additive manufacturing holds the promise of propelling mining tools into a new era of enhanced performance and longevity. WC-Fe, Ni-BASED MATRIX COATINGS Mining tool manufacturers are on the lookout for cutting-edge coating materials as a result of the pursuit of improved wear resistance and increased durability[6]. The development of WC-Fe, Ni-based matrix coatings is a key competitor in this field. Using the advantages of additive manufacturing, notably laser metal deposition (LMD), has allowed for the homogeneous and dense deposition of these coatings, greatly enhancing wear resistance[7]. A further improvement in overall performance has resulted from the precise manipulation of deposition parameters, which allowed for the customization of coating thickness and composition. Notably, the results demonstrated the precise distribution of carbide particles inside the matrix, highlighting the success of the additive manufacturing process in achieving homogeneity (Fig. 2 and 3). One of the study’s outstanding results was the careful control of the deposition parameters, which allowed customizing coating thickness and composition. This granular control has significantly improved coating performance as a whole, demonstrating the possibility to customize coatings to particular application requirements. A further finding from the examination into the heat-affected zone (HAZ) highlighted the accuracy and effectiveness of the additive manufacturing process by revealing very low levels of dilution. To determine the hardness of the HAZ[1], micro hardness testing (Table 1) was used, further demonstrating the effectiveness of the WC-Fe, Ni-based matrix coatings in improving tool durability. The findings highlight not only the technical viability but also the remarkable performance improvements made possible by the incorporation of additive manufacturing techniques in the production of mining tools, positioning WC-Fe, Ni-based matrix coatings as a game-changing development in the quest for increased tool longevity and decreased maintenance costs. CONCLUSION Additive manufacturing is a paradigm-shifting force in the fabrication of mining tools, bringing with it unimaginable possibilities. Combining cutting-edge additive manufacturing processes with cutting-edge coating materials like WC-Fe and Ni-based matrices offers a viable path toward improving tool performance, durability, and competitiveness. The mining industry may embrace this digital transformation to strengthen its position in the global economy by overcoming obstacles through skill development, careful material selection, and rigorous Fig. 2 – LMD hardfaced layer in unetched condition. Fig. 3 – LMD hardfaced layer etched with 2% nital.
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