Coating, Repair and Additive Manufacturing

Rapid Alloy Development

Production of high-performance components

The systems and process expertise of ponticon enables industry-grade application of 3D-EHLA technology for the first time. This technology is utilized whenever special requirements regarding wear, corrosion and temperature resistance of high-performance components cannot be achieved with conventional methods for coatings, repair and additive manufacturing due to limited material availability, insufficient build-up rates or too much post-processing effort. Applications are rooted in turbomachinery, aerospace, tooling, mining, oil&gas and automotive industry as well as in generation and storage of renewable energy.

Depending on the application, the pontiCOAT®, pontiFIX® or pontiBUILD® technologies are used with an application-specific material.

Application Examples

Rapid Alloy Development

In addition to the individualized, industrial production of metallic components, the 3D EHLA process enables the development and processing of new types of alloy systems. Thanks to the nozzle-based powder feed, existing alloy systems and elements can be processed with little effort in any composition to form dense test specimens. The development effort is drastically reduced when using the presented workflow, as numerous test specimens in a wide range of chemical compositions are produced within a few hours. Development cycles for novel materials are thus significantly shortened, as melts no longer have to be generated and analyzed on the conventional development route on a laboratory scale.

Workflow of pontiMAT® Technology for Rapid Alloy Development

In addition to the chemical composition of the processed material system, the microstructure resulting in the component depends significantly on the cooling rate in the process. Due to the highly dynamic kinematics, users of the pE3D system benefit from selectively adjustable cooling rates as part of the pontiMAT® technology. Thus, for the first time, the microstructure created during solidification can be actively influenced by means of the 3D EHLA process.

The wide range of adjustable cooling rates enables the emulation of solidification conditions as they prevail in LPBF or conventional DED processes. The pontiMAT® technology is therefore ideally suited for the agile screening of novel alloy systems, the validation of simulatively determined material properties, and the processing of high entropy alloys and amorphous metals.

Cooling Rates of Additive Manufacturing Processes