Development of an Innovative Laser Assisted Coating Process for Extending Lifetime of Metal Casting Dies

50496-98-I Development of an Innovative Laser Assisted Coating Process for Extending Lifetime of Metal Casting Dies--Karta Technology, Inc., 1892 Grandstand, San Antonio, TX 78238-4507; (210) 681-9102 Dr. M. Govindaraju, Principal Investigator Mr. Thomas Tower, Business Official DOE Grant No. DE-FG03-98ER82604 Amount: $74,931 Casting dies used in the metal casting industry fail due to thermal fatigue cracking accompanied by the presence of residual tensile stresses, corrosion, erosion, and wear of die surfaces. Die failure results in lost production time, reduction in quality of casting, and expensive replacement costs. Surface coatings can provide the necessary protection for extending die life, since most damage occurs at the contact surface of the die with the molten metal. This project will develop an innovative laser coating technology for depositing complex protective coatings on dies to improve their performance and extend their life. Phase I will evaluate the technical feasibility of laser processing for improving die performance. The technique involves laser shot peening to eliminate the surface residual tensile stresses and a laser glazing process to deposit a protective coating. The chemical, physical and surface properties of these coatings and performance of the coated dies will be evaluated in tests involving repeated exposure to heating and cooling cycles. Commercial Applications and Other Benefits as described by the awardee: Coatings produced by this laser processing are expected to possess high corrosion, oxidation, and wear resistance. The technology developed in this research can have a significant impact on the casting industry by saving the material costs involved in replacing dies, reducing downtime, and improving quality. The technology is versatile and can be extended to material or components used in other industrial applications._