Development path of customized materials
The development path begins with identifying material performance requirements and designing alloy compositions on demand, focusing on powder processing with reduced use of critical raw materials.
Metallurgical and thermodynamic modelling supports optimized design, followed by the selection of an appropriate powder production route by mechanical alloying to ensure proper morphology and purity.
Initial lab testing is performed internally using specimens obtained by powder metallurgy processes, thermal sprayed coatings or laser deposition to validate baseline properties.
Pre-industrial prototyping is then carried out with external partners under semi-industrial conditions.
Comprehensive material characterization is conducted both internally and externally, assessing microstructure, mechanical properties, and process compatibility.
Product validation follows, using customer-specific test cases to confirm real-world performance. Industrialization proceeds in collaboration with the customer, integrating the new material into powder processing workflows i.e. press and sintering, thermal spraying, hot press, HIP etc.
Finally, the powder production is scaled up in controlled batches to meet industrial demand, ensuring performance consistency, quality control for widespread application.
This development meets the need for thick, wear-resistant coatings on components used in high-abrasion environments like quarry and mining equipment, where maintenance requires major disassembly. Traditional thermochemical surface treatments such as cementation or nitriding are unsuitable due to their limited thickness and durability.
The proposed solution is a thick (≥1 mm) Fe-Cr-based self-fluxing alloy coating applied via thermal spraying followed by remelting (fusing) to form a strong metallurgical bond with the substrate. The coating provides abrasion and erosion resistance, crack tolerance, and structural integrity under dynamic load conditions. It enables dual functionality: surface protection while maintaining a hardenable core (providing high load-bearing capacity). The alloy is engineered to prevent crack propagation, requires minimal post-treatment, and offers a cost-effective alternative to hardfacing or diffusion treatments, filling a key market gap.
Alloy development begins at lab scale by adjusting the proportions of alloying elements to fine-tune remelting temperature and microstructural evolution, including the precipitation of hard phases for abrasion resistance.
Thermodynamic modeling and melting trials serve to optimize the formulation targeting dense, crack-resistant coatings upon remelting.
Spraying conditions (flame/HVOF) and fusing treatments (torch, furnace, laser) are evaluated which minimize porosity while optimizing bonding quality and dimensional stability.
A small-scale series of components is coated and remelted under varied conditions to evaluate efficiency of deposition, coating thickness control, and surface finish, followed by mechanical testing (hardness, adhesion) and metallographic analysis.
Finally, operational field testing in quarry or mining equipment assesses wear rate, downtime reduction, and coating durability, confirming maintenance-free, high-performance operation in harsh environments.
This development targets the demand for stainless steel semi-finished products that combine high wear resistance—comparable to cold work tool steels—with outstanding corrosion resistance in aggressive environments, for applications in the food processing industry. Even advanced stainless steels often fail to meet both criteria simultaneously, leading to frequent replacement or compromised performance.
The proposed solution is a reinforced stainless steel, designed and manufactured via mechanical alloying, to deliver enhanced durability, processability, and high corrosion stability.
Alloy development begins at lab scale by judiciously tuning the incorporation of finely dispersed ceramic reinforcements into an austenitic stainless-steel matrix. The proportions of hard phases are optimized to balance grain refinement, wear resistance, and thermal stability while maintaining sufficient ductility for downstream processing.
Selected compositions are consolidated via Hot Isostatic Pressing (HIP) to ensure near-full densification. Post-HIP samples undergo microstructural and mechanical characterization (hardness, wear, corrosion resistance), as well as thermal stability assessments.
Heat treatments are applied to tailor hardness, toughness, and microstructural homogeneity.
Processability is validated through hot plastic deformation trials, assessing workability limits and final surface finish. The resulting steel demonstrates superior wear and corrosion resistance while remaining compatible with industrial forming operations.
Field validation in food processing equipment asses long-term durability, reduced maintenance needs, and enhanced product lifetime.
MBN offers full support in customizing alloy composition and processing routes to match specific operating conditions and customer requirements.
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