Leading innovation and industry uptake of the extreme high-speed laser application (EHLA) process

The extreme high-speed laser application (EHLA) is a metallic coating process recently developed (2017) in Germany by Fraunhofer ILT. It has received multiple awards and gained significant industrial interest. This has led to strong interest, from the proposal applicant, TWI and its industrial members (both in the UK and overseas); with the EHLA approach now an integral part of TWI additive manufacturing (AM) strategy roadmaps. Currently, there is no capability in the UK to support industry uptake and offer services, expertise or process development in relation to EHLA processing. To bridge this gap, this application is focused on realising the aspirations of the proposer and to building and developing a team to direct and undertake industrial focused research programs on the EHLA process - covering both existing/known capabilities and extensive future potential.
The project will require 4 years and will cover the following key aspects:
Acquisition and integration of suitable processing equipment as an enabler for EHLA innovation.
Build, train and develop an expert team to drive and develop EHLA
Investigate the capability of EHLA for coatings, repair and high-speed additive manufacturing
Disseminate a portfolio of case studies to TWI industrial members and the wider academic and industry communities.
Technology Concept
The EHLA technology is capable of applying metallic coatings of 10 um to 300 um thick per layer at a maximum coverage rate of 250 cm2/min. Conventional laser metal deposition coverage rates are 10-40 cm2/min. This is achieved by melting the powder prior to reaching the substrate, thereby reducing the time/energy that would otherwise be needed to invoke melting of the substrate. The resultant quality of coating (>99.9% dense, metallurgically fused and defect free), can be considered superior to that of thermal spray technologies. The process is also an economic and more environmentally friendly alternative approach to hexavalent chromium plating.
Project concept
To achieve the goals of the project and aspirations of the proposer, FLF funding will enable the setup of an EHLA facility and appropriately, resource industrial focused research and innovation. The research will include high-speed coatings, metal additive freeform manufacturing, repair, and dissimilar material joining. The project will initially establish fundamentals of the process- and resultant material characteristics. Some of the expected, diverse, applications from current industrial engagement and support include:
Next generation car brake discs
Hexavalent chrome plating replacement, such as hydraulic shafts and offshore components.
Hardfacing coatings of hard alloy or MMC materials including, valve seats and discs in gate valves valve stems, cylinders and tooling.
Repair of blisks and blades for aerospace and energy applications.
Impact
FLF funding will significantly accelerate the introduction and operation of a first UK centre focused on giving industrial support to the EHLA process. It will also accelerate the career profile of the proposer and establish Josh Barras as a leading authority across the globe for the EHLA technology.
This new disruptive technology has strong opportunities for UK and EU markets in many industrial sectors including automotive, offshore, energy, mining and drilling, and aerospace. With the technical and economic advantages of the EHLA process, the technology will create new opportunities and is expected to capture a large percentage of hard chrome plating and thermal spray markets. EHLA also has the potential to influence and disrupt a wider number of markets across coatings, repair, and additive manufacturing.
The project is expected to create growth at TWI and into industrial companies following technology uptake. Within the first two years, TWI expects to create 2 new jobs and additional project income of >£1M, increasing to >£3M within 4 years, and >£5M and 6 new jobs within 8 years.

Specific measures for achieving industrial impact to be undertaken during the fellowship are:

TWI resources to enhance impact potential - TWI will become a centre of excellence within the UK for high-speed laser deposition and extend its current global reputation in laser metal deposition; being a provider of excelling expertise and capability for the UK manufacturing industry across a number of sectors. TWI will back a three-year core research programme (CRP) project, using internal funding allocated by TWI's membership research board. CRP projects are visible to all TWI industrial member companies (700) and provide a strategic method for dissemination and visibility to enable growth opportunities for the EHLA process. All results and the published Industrial Member reports are peer reviewed by representatives of the Industrial Members before release. These results can only be accessed by Industrial Member companies (unless published via papers to open journals).

Engagement with Industrial End-Users - Process innovation will be directed by industrial need, which will be established and detailed through the involvement of key industrial partners as end-users. The industrial partners will bring a shared, non-conflicting interest that will direct the development of the EHLA technology and enhance the project's outcomes. End-users will be encouraged to direct the research of material and applications throughout the project. Collaborating with end-users on specific case studies will improve TWI's awareness of manufacturing requirements and inspire further innovation of the EHLA technology.

Engagement with key industrial suppliers/stakeholders - Industrial involvement will be formalised with quarterly Steering Group meetings. These meetings will be an integral part of the fellowship in order to ensure it remains in line with the needs and requirements of industry to ensure maximum impact.
Hornet Laser Cladding BV is the main supporting supplier in the project, having guaranteed to supply a bespoke EHLA coatings system to TWI (free of charge).

Conferences and public engagement - To ensure that the fellowship can benefit from the maximum academic, industrial and public exposure, the applicant will aim to publish results at internationally renowned conferences, workshops and leading journals. Papers will be presented at academic and practitioner conferences and published in high impact factor journals focused on materials processing and performance. The EHLA team will have the resource to attend at least one major international conference and circa three UK conferences per year, and will aim to present research updates and breakthroughs to capture large audiences of industry and academia. Additionally, TWI hosts its own additive manufacturing symposium to around 120 industrial attendees each year and this will be a strong opportunity for industrial engagement for the EHLA technology. The Fellow and EHLA team will produce peer-reviewed publications for major project developments and research findings
Market Examples - the global disc brake market is valued at over £6bn and increasing year on year. With new regulations on the horizon there is an ever-increasing demand and necessity for coated brakes. Working alongside key industrial end-users in this sector will help to realise EHLA's potential to disrupt current coating technologies and capture a large percentage of the £6bn market.
EHLA's potential is not limited to this specific market, and is ideally suited to revolutionising the general surface treatment market. If EHLA captured just 5% over the next ten years, then its revenue in the surface treatment sector would amount to roughly £1 billion per year.
[1] Global Industry Analysts, Inc.: Electroplating - a global strategic business report, 2014
[2] Persistence Market Research: Global Market Study on Thermal Spray Coatings, 2016
[3] Wohlers Annual Report:3D Printing and Additive Manufacturing Worldwide, 2018