Dr.-Ing. Haneen Daoud

Deputy Head of Metals

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Dr.-Ing. Haneen Daoud

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Case Study ComDiscTool

Sustainable Powders for Wear-Resistant Coatings

The increasing electromobility raises the raw material dependency of the automotive industry. For wear-resistant components, high-performance coatings are crucial. NMB developed sustainable Fe-based coatings (Fe-Al-X) and an efficient manufacturing process to substitute critical raw materials such as nickel, cobalt, and tungsten. 

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Motivation

Substitution of critical materials based on nickel and cobalt

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Solution Approach

Development of alternative Fe-Al-X materials

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Approach

Development of sustainable materials for coatings and additive manufacturing

Optimization of the arc spraying process

Conducting a Life Cycle Assessment to evaluate the manufacturing processes

Motivation

Substitution of Critical Materials

The automotive industry is facing an increasing dependency on raw materials caused by the rise of electromobility. In the production of wear-resistant components and sheet metal forming tools, coating materials and processes are crucial for performance, sustainability, and lifespan.

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Solution Approach

Fe-Al-X Materials

NMB has developed sustainable composite powders and innovative manufacturing processes for highly wear-resistant coatings. A novel coating composition based on Fe (Fe-Al-X) has been developed to reduce dependence on critical raw materials such as nickel, cobalt, and tungsten. A thermal arc spraying process has been introduced that achieves an efficiency of 60% for particles in the range of 40-150 µm without the formation of hollow spheres.

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Approach

Substitution of Critical Materials through Innovative Fe-Al-X Alloys: Sustainability and Performance in Focus

  • Focus on resource-saving materials with high performance
    The focus is on developing resource-saving materials that ensure high performance and reliability in demanding applications despite the reduced use of critical raw materials. Through intelligent material combinations and the use of sustainable raw materials, ecological aspects are aligned with technical requirements to realize future-proof coating solutions.
  • Improvement of process efficiency and powder quality through targeted adjustments
    The improvement of process efficiency and powder quality is achieved through targeted adjustments to process parameters, such as temperature control, gas flows, and feed mechanisms, to achieve optimal particle morphology and distribution. This optimization enables uniform and high-quality layer formation, leading to a more sustainable and economical coating technology overall.
  • Analysis of ecological impacts along the entire manufacturing process
    The analysis of ecological impacts along the entire manufacturing process includes the systematic assessment of energy and raw material consumption as well as waste streams at each process stage – from the raw material to the coating to post-processing. The goal is to identify ecological hotspots and sustainably improve the environmental balance through targeted measures such as process optimizations or material substitutions.

Project sponsor: Federal Ministry for Economic Affairs and Energy (BMWE), Central Innovation Program for SMEs (ZIM) | Funding code: KK5027512JN3
Partner: HUBER-tec GmbH