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Sustainability of Metal Structures via Spray-Clad Remanufacturing

  • Toward Resources and Processes Sustainability
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Abstract

Structural reclamation and remanufacturing is an important future design consideration to allow sustainable recovery of degraded structural metals. Heavy machinery and infrastructure components subjected to extended use and/or environment induced degradation require costly and time-consuming replacement. If these parts can be remanufactured to original tolerances, and returned to service with “as good or better” performance, significant reductions in materials, cost, and environmental impact can be achieved. Localized additive restoration via thermal or cold spray methods is a promising approach in recovering and restoring original design strength of degraded metals. The advent of high velocity spray deposition technologies has allowed deposition of near full density materials. In this review, the fundamental scientific and technological elements of such local additive restoration is contemplated including materials, processes, and methodologies to assess the capabilities of such remanufactured systems. This points to sustainable material reclamation, as well as a route toward resource and process sustainability.

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Fig. 1

Photo courtesy: Legacy applications (a), reproduced with permission of Oerlikon Metco;15 Protective metalizing on Forth Rail Bridge (b), Andrew Bell/Wikipedia Commons; Front mining machine strut (c), Dan Sordelet/Caterpillar; Turbine compressor boss with HVOF repair (d), Jan Wigren/GKN Aerospace; Engine spray bore using RotaPlasma HS1 (e), Oerlikon Metco

Fig. 2

Data supplemented with results from Refs. 20, 25,26,27

Fig. 3

Data supplemented with results from Refs. 21, 28

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Acknowledgements

The authors would like to acknowledge Dr. Andrew Vackel, Dr. Xiaotao Luo, and Dr. Brian Choi for their assistance in development of these methodologies and spray practices, as well as Dr. Vackel’s collaboration with the Canadian National Research Council (CNRC) in Boucherville, Canada and at VTT, Finland in producing some of the evaluated coatings. Support comes from the Industrial Consortium for Thermal Spray Technology at Stony Brook University.

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Authors and Affiliations

  1. Center for Thermal Spray Research, Department of Materials Science and Engineering, Stony Brook University, Stony Brook, NY, 11794, USA

    Gregory M. Smith & Sanjay Sampath

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  1. Gregory M. Smith
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  2. Sanjay Sampath
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Correspondence to Gregory M. Smith.

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Smith, G.M., Sampath, S. Sustainability of Metal Structures via Spray-Clad Remanufacturing. JOM 70, 512–520 (2018). https://doi.org/10.1007/s11837-017-2676-0

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  • DOI: https://doi.org/10.1007/s11837-017-2676-0

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