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Study of tungsten carbide (WC) coatings produced by DED Direct Energy Deposition in AISI H13 and 4140 steels

Grant number: 19/26362-2
Support type:Scholarships in Brazil - Post-Doctorate
Effective date (Start): April 01, 2020
Effective date (End): March 31, 2022
Field of knowledge:Engineering - Mechanical Engineering - Manufacturing Processes
Principal Investigator:Reginaldo Teixeira Coelho
Grantee:Fábio Edson Mariani
Home Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
Associated research grant:16/11309-0 - The study, development and application of a hybrid process: Additive Manufacturing (AM) plus High Speed Machining/Grinding (HSM/G), AP.TEM


Manufacture of parts and their tools for serial and exclusive production, such as molds and dies, faces a new challenge: high precision requeriments, flexibility and high production speed. This research project aims to produce cobalt agglomerated tungsten carbide (WC-Co) coatings in AISI H13 and 4140 steels through additive manufacturing (AM) using laser powder-fed system Direct Energy Deposition (DED) method, in comparison to coatings obtained by HVOF thermal spray. The AM-DED laser powder-fed System process is a new technology and for the development of part coatings a complete study of deposition parameters is required for the use of different raw materials. The coatings produced will be evaluated in order to verify the manufacturing parameters, and changes in the process may be proposed to ensure that the deposited material has properties similar to or superior to coatings obtained by thermal spraying, reducing limitations, costs and production times. Additionally, the proportion of Co for the deposition of powders will be modified. The coatings produced will be characterized using microstructural techniques (SEM/EDX and laser confocal), X-ray diffraction and fluorescence, as well as hardness, adhesiveness (coating/substrate) and microadhesive and microabrasive wear tests. The interconnections between these technologies and process quality is an important step in the development of coatings produced by AM. The expected result is the obtaining of a homogeneous coating, of excellent adhesion to the substrate and high resistance to wear. The knowledge acquired during the project is intended to be applied to develop WC-Co coatings in thermoplastic injection molds as well as steam turbine blades for power generation with sugarcane bagasse. (AU)