Additive Manufacturing of Welded Overlay

Additive Manufacturing of Welded Overlay

The Project will investigate and trial automated/robotic wire arc additive manufacturing to fabricate welded hard-facing overlay on Q&T steels. The Project Team, consisting of UOW’s Project Leader Professor Huijun Li and Associate Professor Zengxi (Stephen) Pan, and Bisalloy’s Technical and R&D Manager Dr Dake Yu and Technical Manager (Armour) Dr Willy Pang, bring together significant experience in advanced steel-related research and industrial research experience related to Q&T product development.

Through experimental design and trials, the project will develop an optimised methodology for high hardness (wear) and toughness (impact, blast) of welded overlay which has significantly improved performance. It will then focus on the development of an automated hard-facing solution for which a robot operator can easily program and which does not require a high level of welding skill and knowledge.

01/08/2021- 31/01/2025

Hard-facing is a process where one or multiple layers of different materials, with unique properties, are deposited on the base metal to significantly improve its surface performance, such as wear and corrosion resistance, or to repair the worn components. In industrial sectors, equipment is routinely subjected to extreme working conditions such as severe wear, impact, and high temperature, which requires component materials with enhanced performance. However, it is not efficient to manufacture the entire component with these more costly materials. Hard-facing enables a superior price-performance manufacturing process by depositing hard-facing consumable materials on surfaces or in critical positions of the less expensive base material.

For steel consumers, the benefit is a product with improved performance while also having the potential to reduce maintenance, repair, and operational costs via prolonged service life, due to the ability to repair and restore components via hard-facing overlay. For Bisalloy, the anticipated outcome of this research is the potential to appreciably improve market share, product quality and reputation through technology development, which will ultimately enhance Bisalloy’s competitiveness in the international market. Sophisticated automated processes will also enable a higher level of product quality consistency, reduced labour, and improved health/safety environment for operators.

5

University of Wollongong

Status

Ongoing

Principal Lead

Prof Huijun Li

Prof Huijun Li obtained a PhD degree in 1996 from the University of Wollongong; He has 25 years’ research experience in materials science and engineering. He has published 5 book chapters and more than 400 papers over his career in the field of welding metallurgy, additive manufacturing, alloy development, surface engineering, nuclear materials and microstructure characterization.

Professor Huijun Li joined CRC Welded Structures research activities from 1995 to 2005, where he gained considerable experience on welding high strength line pipe steels, Q&T steels, stainless steels and heat resistant steels. He has also been involved in the revision of WTIA (Welding Technology Institute Australia) Technical Note 1 “The Weldability of Steels”, this technical note gives recommendations for the control of HAZ hardness and avoidance of cold cracking in carbon, carbon-manganese and low-alloy steels. After joining UOW in 2008, he has been heavily involved in DMTC and EPCRC research, including welding light armoured vehicles, naval surface ships and high strength line pipe steels.

Professor Li ‘s major role in the Steel Hub research is to investigate “Automated additive wire arc additive manufacturing to create multilayer hard-facing specialty steels with improved performance”,. Due to the mechanical and microstructural impact of additive manufacturing on processed Q&T steels and the need to ensure product quality, the project will quantify the correlation between mechanical properties and microstructure of cladded lay and the Heat Affected Zone over a wide range of welding parameters.

Researchers

Prof Huijun Li

Prof Huijun Li obtained a PhD degree in 1996 from the University of Wollongong; He has 25 years’ research experience in materials science and engineering. He has published 5 book chapters and more than 400 papers over his career in the field of welding metallurgy, additive manufacturing, alloy development, surface engineering, nuclear materials and microstructure characterization.

Professor Huijun Li joined CRC Welded Structures research activities from 1995 to 2005, where he gained considerable experience on welding high strength line pipe steels, Q&T steels, stainless steels and heat resistant steels. He has also been involved in the revision of WTIA (Welding Technology Institute Australia) Technical Note 1 “The Weldability of Steels”, this technical note gives recommendations for the control of HAZ hardness and avoidance of cold cracking in carbon, carbon-manganese and low-alloy steels. After joining UOW in 2008, he has been heavily involved in DMTC and EPCRC research, including welding light armoured vehicles, naval surface ships and high strength line pipe steels.

Professor Li ‘s major role in the Steel Hub research is to investigate “Automated additive wire arc additive manufacturing to create multilayer hard-facing specialty steels with improved performance”,. Due to the mechanical and microstructural impact of additive manufacturing on processed Q&T steels and the need to ensure product quality, the project will quantify the correlation between mechanical properties and microstructure of cladded lay and the Heat Affected Zone over a wide range of welding parameters.