Selection of a suitable wear-resistant metal matrix composite for remanufacturing continuous miner cutter (CMC) sleeves via a two-step laser-based technique

作     者：Lindsay, Emmanuel Efemena Akintunde, Idris Babatunde Olakanmi, Eyitayo Olatunde Prasad, Raghupatruni Ventaka Satya Botes, Annelize Pityana, Sisa Lesley Skhosane, Samuel 

作者机构：Botswana Int Univ Sci & Technol Dept Mech Energy & Ind Engn Palapye Botswana Botswana Int Univ Sci & Technol UNESCO Chair Sustainable Mfg & Innovat Technol UCo Private Mailbag 16 Palapye Botswana Botswana Int Univ Sci & Technol Adv Mfg & Engn Educ AMEE Res Grp Palapye Botswana Botswana Int Univ Sci & Technol Dept Chem Mat & Met Engn Palapye Botswana Fed Univ Technol Dept Mat & Met Engn Minna Nigeria Nelson Mandela Univ Dept Mech Engn Port Elizabeth South Africa CSIR Laser Enabled Mfg Res Grp Pretoria South Africa MTL BldgRoom 038 ZA-6001 Port Elizabeth Eastern Cape South Africa CSIR Pretoria South Africa 

出 版 物：《CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY》 (CIRP J. Manuf. Sci. Technol.)

年 卷 期：2025年第60卷

页      面：165-181页

核心收录：

学科分类：08[工学] 0802[工学-机械工程] 

基　　金：Education, Audiovisual and Culture Executive Agency (EACEA) [2019-1973/5, 614655] Botswana International University of Science and Technology (BIUST) [DVC/RDI/2/1/7V (143)] African Laser Centre (ALC) [HLHA23X task ALC-R016] 

主　　题：Metal matrix composites (MMCs) Two-step laser-based remanufacturing Laser cladding Gas metal arc welding (GMAW) overlay Hybridisation effect Solid solution strengthening TiC umbrella-like network 

摘      要：The premature failure of continuous miner cutter (CMC) sleeves in underground coal mining necessitates remanufacturing to enable a closed-loop system and enhanced sustainable mining operations. However, a techno-economic analysis conducted revealed that exclusively using laser cladding (LC) to remanufacture failed sleeves is not economically viable. Thus, this research aims to explore a two-step laser-based remanufacturing technique that incorporates gas metal arc welding (GMAW) and LC, as well as identify suitable wear-resistant metal matrix composites (MMCs) for restoring damaged sleeves. Consequently, an LC process was used to deposit three MMC materials onto optimised GMAW overlays. A comparative analysis of the manufactured MMC coatings revealed that WC/TiC/AISI4340 coating exhibited a well-consolidated, crack-and pore-free microstructure and a superior microhardness of 931 HV0.5 compared to WC-and TiC-reinforced composites, which had average hardness values of 670 HV0.5 and 744 HV0.5, respectively. Additionally, the WC/TiC/AISI4340 coating demonstrated an excellent low wear rate (0.0007 g/s) comparable to TiC-reinforced coating, and a propensity to extend the sleeve s lifespan by a factor of four. These enhancements are attributed to the formation of an umbrella-like network of TiC, predominantly distributed in the coating top region and solid solution strengthening [(Ti, W)C] caused by the partial dissolution of WC/TiC carbides and their precipitation into the eutectic carbide network within the interdendritic grain regions. Hence, combining GMAW and LC processes with WC/TiC/AISI4340 presents a promising remanufacturing strategy for restoring mining equipment, offering improved performance, longer lifespan, and economically viable and sustainable mining operations.