Project Fact Sheet

METAL-MATRIX COMPOSITES AND THERMAL SPRAY

COATINGS FOR MINING MACHINES
ABRASION-RESISTANT MATERIALS WILL REDUCE SCHEDULED
DOWNTIME BY 50%
Advancedabrasion-resistantmaterialswillreducescheduleddowntimeby50%by
doublingthelifeofwearcomponents.Thisprojectinvolvesthedevelopmentand
testingofabrasion-resistantmaterialsforminingequipment.Thesematerials
includethermalsprayedhardfacingcoatingsandsteelmetalmatrixcomposites
(MMCs).
Thermalspraycoatingsarefavoredoverweldhardfacingbecausetheypermit
greaterflexibilityofcomposition. Inaddition,thesprayedpartsaresubjectto
lowerandmoreuniformheatinputduringprocessingresultinginlessdistortionand
ashallowerheataffectedzone. Thisprojectwillexplorethebenefitsofsprayed
hardfacingcoatings.Thesecoatingsarefusedtothesubstrateanddensified
usingahigh-fluxinfrared-basedheatingsource.Thispostinfraredprocessingis
referredtoashigh-densityinfrared(HDI)transient-liquidcoating(TLC).
Afewsteelmetalmatrixcompositescurrentlyexistinthemarketplace.Someof
thebestqualitycompositematerialsareproducedusingpowderprocesses.
However,suchprocessesarenoteconomicallyfeasibleforthelargewear
componentsusedinmining.Caterpillarhasproventhefeasibilityofahybrid
pressureinfiltrationcastingprocessthatuseslowcostceramicdielinersandsteel
toolingtofabricatelowporositysteelMMCs. Thisprojectwilldevelopthehybrid
pressurecastingprocesswithparticularfocusonprocessoptimization,selective
reinforcement,andoptimizationofthecompositesystemswear-resistanceand
toughness.
BUCKET
Improved mining productivity though material innovation.
MINING MINING
MINING MINING MINING
BENEFITS
Reduces energy needed to
makereplacementpartsby
doublinglifeofexistingparts
Decreases frictional losses by
maintaining optimal shape and
through proper placement of
coating or hard reinforcement
Reduces equipment downtime
asaresultofdoublinglifetimeof
wear components
APPLICATION
Advanced materials apply to
researchprioritiesdefinedbythe
miningindustrysuchasnew
materialsforwear,construction,
and process application.
OFFICE OF INDUSTRIAL TECHNOLOGIES
ENERGY EFFICIENCY AND RENEWABLE ENERGY U.S. DEPARTMENT OF ENERGY
Project Description
Objective: Todevelopandtestadvancedabrasion-resistantmaterialsformining
equipmentusingtwomethods:(1)ahybridpressurecastingprocessforparts
comprisedofsteelmetalmatrixcomposites,and(2)anovelthermaltreatmentof
partsthathavebeenspraycoated. Theseabrasion-resistantmaterialswillreduce
operatingcostsandincreaseproductionbyreducingmachinerydowntime.
ForthefirstyearofresearchCaterpillarInc.willworkcloselywiththeOakRidge
NationalLaboratorytoapplytheHDI/TLCprocesstoCaterpillarcomponents.In
parallel,CaterpillarwillworkwithSt.LouisMetallizingtodevelopthemasa
supplierofthistechnology.Also,duringthefirstyear,effortswillbemadetobegin
identifyingindustrialpartnerswillingandcapableofpursuingthehybridpressure
infiltrationprocess.Caterpillarscurrentpartneringwithleadingsteelfoundriesmay
aidthiseffort.Oncedeveloped,industrypartnerswouldbeinvolvedinfurther
enhancementandoptimizationofthematerialsystemsandprocess,ensuringthat
manufacturabilityissuesareaddressedandofferingapotentialtofurther
acceleratedevelopmentoftheseproducts.
Progress and Milestones
Activitiestobecompletedinthisprojectinclude:
Evaluateprocessingandmaterialcosts,aswellastheeconomic
competitivenessoftheprocesses.
Identifythematerialconstituentsand,forcomponents,thehardmaterials
placementtoprovidetheoptimalcombinationofabrasionresistanceand
structuralproperties.
Developthehybridpressureinfiltrationcastingprocesswithemphasis
placedonceramicdieliners,hardparticlepreforms,andcastingprocess
developmentandoptimization.
Furtherenhancethecoatingperformancebyaddressingtwofactorsthat
havelimitedtheirapplicationinmining:interfacialbondstrengthandlow
coatingdensity.
Examinetheabrasion-resistanceandintegrityofthematerialsystems.
Fabricateandfieldtestthecomponents.
COMPOSITES AND COATINGS
PROJECTPARTNERS
CaterpillarInc.
Peoria,IL
Albany Research Center
Albany, OR
Oak Ridge National Laboratory
OakRidge,TN
St.LouisMetallizing,
St.Louis,MO
StateUniversityofNewYork-
StonyBrook
StonyBrook,NY
University of California-
Santa Barbara
SantaBarbara,CA
FOR ADDITIONAL INFORMATION,
PLEASE CONTACT:
OfficeofIndustrialTechnologies
Clearinghouse
Phone: (800) 862-2086
Fax:(360)586-8303
clearinghouse@ee.doe.gov
Visitourhomepageat
www.oit.doe.gov/mining
OfficeofIndustrialTechnologies
Energy Efficiency
and Renewable Energy
U.S.DepartmentofEnergy
Washington,D.C. 20585
June 2001
(Left)Steelmatrixcomposites.(Right)Thermalspraycoatingprocess.