Additive Manufacturing of Engineering Steels using Flux-cored Wire
Lead Research Organisation:
University of Surrey
Department Name: Mechanical Engineering Sciences
Abstract
Corewire Ltd manufacture flux-cored wire welding consumables. They also manufacture equipment which uses these wire consumables to repair and resurface a variety of high wear resistance steel components. This includes dies for the manufacture of automotive components and rolls used in the production of rolled metal.
This project will explore how this current technology and capability can be evolved into additive manufacturing of full components. A key thread will be establishing and quantifying the specific challenges to moving from resurfacing by depositing a few layers of weld metal to full component manufacture using tens or even hundreds of layers. The project will therefore commence with the deposition of current resurfacing solutions (first six months) and progress with the manufacture of increasingly challenging steels and prototypical components. The challenges include higher performance steels, increased reinforcement, compositional grading, more complex geometry, etc. The research programme will include microstructural characterisation, experimental stress-strain measurement, modelling of stress-strain accumulation during additive manufacture and alloy development. High wear resistance steels will be the focus of the research programme and the research is likely to include some wear evaluation and fracture toughness testing.
Alongside the scientific, technological and engineering programme the project will work with a range of existing customers and new industrial partners to identify specific applications of this emerging additive manufacturing capability.
This project will explore how this current technology and capability can be evolved into additive manufacturing of full components. A key thread will be establishing and quantifying the specific challenges to moving from resurfacing by depositing a few layers of weld metal to full component manufacture using tens or even hundreds of layers. The project will therefore commence with the deposition of current resurfacing solutions (first six months) and progress with the manufacture of increasingly challenging steels and prototypical components. The challenges include higher performance steels, increased reinforcement, compositional grading, more complex geometry, etc. The research programme will include microstructural characterisation, experimental stress-strain measurement, modelling of stress-strain accumulation during additive manufacture and alloy development. High wear resistance steels will be the focus of the research programme and the research is likely to include some wear evaluation and fracture toughness testing.
Alongside the scientific, technological and engineering programme the project will work with a range of existing customers and new industrial partners to identify specific applications of this emerging additive manufacturing capability.
Planned Impact
Materials science and engineering is a key 'enabling' discipline underpinning many others. Hence the research engineers (REs) studying for their engineering doctorates (EngDs) as members of the Industrial Doctorate Centre in Micro- and NanoMaterials and Technologies (IDC in MiNMaT) undertake projects that span a large number of industries covering a broad spectrum of materials technologies. Consequentially, the impact of the research undertaken by the REs is wide-ranging.
Given the emphasis placed on solving processing-microstructure-property-performance relationship problems, which are both academically challenging and industrially relevant, the industrial sector is a key beneficiary group for the IDC. Specifically, as the RE is embedded in the sponsoring company, impact is achieved earlier than might be expected for a university-based project. Our current REs have already achieved impact through changes to business practices which have resulted in the creation of new processes or products or improvements to existing ones, ultimately generating economic growth. Our current sponsors have said that the work of the REs has '.helped us enlarge our product range' and '...assisted in guiding and accelerating new product and process development' and that '...successful completion of the project, which is on target, will be of real benefit'.
The shortage of materials graduates has been highlighted in a number of reviews and hence impact for the industrial sector will also be achieved through the training of research engineers, such that they are ready to enter employment and lead the next generation of materials research. A current sponsor comments '..a new recruit into the field, of [name]'s calibre, can only be a very good thing for the UK'.
In terms of the scientific community, impact is and will be achieved via publications in high quality peer-reviewed journals (a mandatory part of the programme) and presentations at conferences (over 30 since the first REs joined the IDC in 2009). These vital routes to dissemination provide a conduit to enable effective knowledge transfer of the research being undertaken in industry to the wider scientific community. Further, the IDC runs a unique annual conference, which provides an additional route to keep our community informed of the latest developments. Additionally, our industrial sponsors really value the opportunity to mix with other sector organisations in a way which they do not do elsewhere. The event also provides an opportunity to attract and engage with new industrial partners, widening the community and supporting the sustainability of the IDC.
Finally, the IDC will have a significant impact on the REs by increasing their employability skills. Specifically, the programme works with industry to ensure that the REs are developing the necessary skills needed by industry. The EngD programme has many benefits for an individual. Principally, the time that the RE spends with their industrial sponsor is key to giving them the context and confidence to operate effectively in the commercial environment. Further, REs benefit from having cohorts through peer-to-peer learning and the enhanced networking opportunities that arise from the many RE, academic and sponsor interactions and, as the IDC matures, the alumni network. Finally, the emphasis placed on personal development and the professional ethos that underpins all IDC activities provides the REs with a firm foundation on which to build the rest of their careers.
Given the emphasis placed on solving processing-microstructure-property-performance relationship problems, which are both academically challenging and industrially relevant, the industrial sector is a key beneficiary group for the IDC. Specifically, as the RE is embedded in the sponsoring company, impact is achieved earlier than might be expected for a university-based project. Our current REs have already achieved impact through changes to business practices which have resulted in the creation of new processes or products or improvements to existing ones, ultimately generating economic growth. Our current sponsors have said that the work of the REs has '.helped us enlarge our product range' and '...assisted in guiding and accelerating new product and process development' and that '...successful completion of the project, which is on target, will be of real benefit'.
The shortage of materials graduates has been highlighted in a number of reviews and hence impact for the industrial sector will also be achieved through the training of research engineers, such that they are ready to enter employment and lead the next generation of materials research. A current sponsor comments '..a new recruit into the field, of [name]'s calibre, can only be a very good thing for the UK'.
In terms of the scientific community, impact is and will be achieved via publications in high quality peer-reviewed journals (a mandatory part of the programme) and presentations at conferences (over 30 since the first REs joined the IDC in 2009). These vital routes to dissemination provide a conduit to enable effective knowledge transfer of the research being undertaken in industry to the wider scientific community. Further, the IDC runs a unique annual conference, which provides an additional route to keep our community informed of the latest developments. Additionally, our industrial sponsors really value the opportunity to mix with other sector organisations in a way which they do not do elsewhere. The event also provides an opportunity to attract and engage with new industrial partners, widening the community and supporting the sustainability of the IDC.
Finally, the IDC will have a significant impact on the REs by increasing their employability skills. Specifically, the programme works with industry to ensure that the REs are developing the necessary skills needed by industry. The EngD programme has many benefits for an individual. Principally, the time that the RE spends with their industrial sponsor is key to giving them the context and confidence to operate effectively in the commercial environment. Further, REs benefit from having cohorts through peer-to-peer learning and the enhanced networking opportunities that arise from the many RE, academic and sponsor interactions and, as the IDC matures, the alumni network. Finally, the emphasis placed on personal development and the professional ethos that underpins all IDC activities provides the REs with a firm foundation on which to build the rest of their careers.
People |
ORCID iD |
| Mark Whiting (Primary Supervisor) | |
| Oliver Whiteside (Student) |