ADVANCED MATERIALS & PROCESSES | NOVEMBER/DECEMBER 2024 27 In the evolving field of sustainable manufacturing, the reuse of materials is an environmental imperative and an economic advantage. Among various materials, metal powders play a pivotal role, especially in the additive manufacturing and thermal spray coating industries. A prime example of innovative reuse is found in the development of hybrid mining tools, which combine conventionally fabricated core material with advanced surface coatings for enhanced durability, using reclaimed nickel-chromium-boron-silicon (NiCrBSi) powder mixed with tungsten carbide (WC)[1]. In industrial settings, especially where precision is the key, metal powder spillage is an unavoidable challenge. For example, in laser metal deposition (LMD), an amount of up to 20 kg powder is fed to the equipment, and almost 20-50% of the powders are spilled out[2], (Fig. 1) depending on the shape and geometry of the part. The spilled-out powders, typically considered waste, are often discarded, leading to both economic loss and environmental impact. This has prompted researchers and manufacturers to explore the viability of reusing these spilled-out powders without compromising the quality of the final product. REUSE OF SPILLED-OUT METAL POWDER FROM LMD IN MAKING HYBRID MINING TOOLS Enhanced mining tool performance is achieved through reclaimed NiCrBSi-WC powders in laser metal deposition that also lowers production costs and reduces environmental impact. Varun Kumar Kurapati* and M. Kalyan Phani* OP Jindal University, Raigarh, India *Member of ASM International A recent study focused on the reuse of spilled-out NiCrBSi powder mixed with WC to develop hybrid mining tools. The process involved collecting the spilled powders, ensuring they were free from contaminants, and blending them in specific proportions to create a composite material suitable for LMD application. To validate the efficacy of using reclaimed powders, extensive metallurgical and microstructural analyses RESEARCH AND DEVELOPMENT: A CASE STUDY NiCrBSi powders[1] are renowned for their excellent wear resistance, corrosion resistance, and high-temperature performance. When combined with WC, the resulting composite material exhibits enhanced hardness and durability, making it ideal for applications in the mining industry where tools are subjected to extreme conditions. Fig. 1 — Schematic representation of laser metal deposition and spilled-out powder.
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