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.