Public Funding for Powderloop Technology Limited

SWRC will develop a new, sustainable manufacturing technology to produce hard-facings for downhole drilling tools. Using a novel in-situ alloying approach based on laser Directed Energy Deposition (DED), an additive manufacturing technology, the project will form highly wear resistant hard-facing coatings, using both pre-alloyed and elemental powders. The hard-facing coating is characterised by a strong metallurgical bond showing a continuous metal-matrix and finely-dispersed hard phase precipitates creating complex microstructure necessary for wear and erosion applications. This has overcome the drawback encountered when using commercial hard-facing tungsten carbide powders. The project is expected to deliver three innovations: 1. Materials innovation -- formulation of new powder composition using sustainable elemental materials for laser processing that undergoes high heating and cooling rates. 2. Process innovation -- application of resource-efficient powder manufacturing technology and automated, highly efficient additive manufacturing process to form near-net shape hard-facings. 3. Product innovation -- high-performance coatings will increase downhole drilling tools efficiency, reduce the frequency for repairs and demand for primary production of high-value components. The innovative laser additive manufacturing process will benefit the environment; the resource-efficient powder manufacturing process will replace high-energy processing and the near-net shape DED will lead to more efficient application of strategic and scarce materials thus minimising waste of expensive at-risk commodities. Localised heating using a laser beam will improve precision and reduce greenhouse gases. In service, the downhole tool will exhibit higher wear performance and will lower energy consumption, whilst its higher longevity will reduce the demand for the primary production of high-value components.

The application of a hardfacing coating to the surface of a component is a common industrial process used to enhance wear, thermal and corrosion resistance. Typical hardfacings processes including thermal spraying and electroplating, and more recently Laser Directed Energy Deposition (DED). The proposed project will develop a new, resource efficient hardmetal powder manufacturing technology and associated hardmetal powders, designed specifically for DED. The 6-months project will remove wasteful and expensive manufacturing stages from conventional hardmetal powder manufacturing. By combining the new materials and DED into a coating manufacturing methodology, significant hurdles and limitations related to carbide decarburisation, coating life, process cost effectiveness, rapid design and testing of new material solutions can be overcome. The project outcomes, while focusing on the DED hardfacings, can be applied to other additive manufacturing and powder metallurgy processes that require high wear resistance and low friction, for both primary manufacturing and repairs. Success in the project will provide disruptive solutions for the hardfacings community and drive the multi-billion-pound MRO sector towards greener and sustainable coatings.