Development of sustainable tubular wires from the reuse of machining waste in hard coatings

• Grant number: 25/04592-7
• Support Opportunities: Regular Research Grants
• Start date: November 01, 2025
• End date: October 31, 2027
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: José Gedael Fagundes Júnior
• Grantee: José Gedael Fagundes Júnior
• Host Institution: Faculdade de Engenharia (FEIS). Universidade Estadual Paulista (UNESP). Campus de Ilha Solteira. Ilha Solteira , SP, Brazil
• Associated researchers: ANDRES MAURICIO MORENO URIBE ; Cibely da Silva Martin Sonvesso ; Juno Gallego ; Vicente Afonso Ventrella

Abstract

The proposal to use tubular wires for the deposition of hard coatings by welding emerges as an alternative for the reuse of waste from conventional machining processes, such as titanium and niobium alloy chips, as well as carbide inserts. Currently, these wastes are primarily discarded as low-value scrap or generate additional costs for proper disposal, representing a waste of potentially valuable materials. In the context of the circular economy, implementing this proposal would allow for the efficient reuse of these wastes, reducing reliance on primary resources and minimizing the environmental impacts associated with their extraction. The composition of titanium and niobium chips, rich in noble elements, and carbide inserts containing tungsten carbide (WC), could be strategically utilized in the formulation of tubular wire flux, promoting the formation of coatings with high wear resistance. Furthermore, these wastes can be used in combination with chromium (Cr) to form mixed carbides, derived from combinations within the Fe-Cr-Ti-Nb-W-C metallurgical system, potentially enhancing the performance of the coatings in terms of abrasive wear resistance. The possibility of obtaining these complex phases opens new perspectives for the development of high-performance welding consumables from recycled materials, making it an economically viable alternative to replace high-cost commercial inputs. The application of this approach would economically enable the creation of surfaces with high tribological performance, using industrial wastes that, until now, have not been efficiently utilized. Thus, the proposal presents itself as a promising solution to transform environmental liabilities into valuable resources for the industry, contributing to sustainability and cost reduction in production. (AU)