TY - JOUR

T1 - Increasing the service life of electrodes for Contact Arc Metal Grinding using additively manufactured metal matrix composites

AU - Mills, Christian

AU - Kreie, Lena

AU - Maier, Hans Jürgen

AU - Hassel, Thomas

N1 - Publisher Copyright: © 2025 The Authors

PY - 2025/9/15

Y1 - 2025/9/15

N2 - This paper explores the application of additive manufacturing to extend the service life of the electrodes used in Contact Arc Metal Grinding (CAMG), a thermal underwater cutting process employed inter alia in nuclear decommissioning. One of the many challenges faced in nuclear dismantling with CAMG is the rapid wear of the electrodes, which requires innovative solutions for increased operational efficiency. Using additive manufacturing, the feasibility of creating customised material solutions tailored to the specific requirements of individual load cases was investigated. The focus of this study was the application of a particle composite material in the circumferential area of the electrode. This successful integration of additive manufacturing techniques with metal matrix composites into the production of electrodes opens up new avenues for improving the performance of the CAMG process. Fused tungsten carbide, chosen for its refractory properties, was incorporated into a copper-based metal matrix through laser-based directed energy deposition (L-DED). The aim was to evaluate the effectiveness of this approach in reducing electrode wear and improving cutting performance. By incorporating fused tungsten carbide, a significant increase in cutting length by a factor of 18 compared to a copper alloy was achieved (0.8 m–14.4 m). In this work, the prevailing wear mechanisms were examined in detail. Wear due to high temperatures was identified. However, mechanical wear for the ignition contact cannot be excluded. The results contribute to the advancement of thermal cutting processes, particularly in the context of nuclear decommissioning, where durable and efficient electrode materials are of paramount importance.

AB - This paper explores the application of additive manufacturing to extend the service life of the electrodes used in Contact Arc Metal Grinding (CAMG), a thermal underwater cutting process employed inter alia in nuclear decommissioning. One of the many challenges faced in nuclear dismantling with CAMG is the rapid wear of the electrodes, which requires innovative solutions for increased operational efficiency. Using additive manufacturing, the feasibility of creating customised material solutions tailored to the specific requirements of individual load cases was investigated. The focus of this study was the application of a particle composite material in the circumferential area of the electrode. This successful integration of additive manufacturing techniques with metal matrix composites into the production of electrodes opens up new avenues for improving the performance of the CAMG process. Fused tungsten carbide, chosen for its refractory properties, was incorporated into a copper-based metal matrix through laser-based directed energy deposition (L-DED). The aim was to evaluate the effectiveness of this approach in reducing electrode wear and improving cutting performance. By incorporating fused tungsten carbide, a significant increase in cutting length by a factor of 18 compared to a copper alloy was achieved (0.8 m–14.4 m). In this work, the prevailing wear mechanisms were examined in detail. Wear due to high temperatures was identified. However, mechanical wear for the ignition contact cannot be excluded. The results contribute to the advancement of thermal cutting processes, particularly in the context of nuclear decommissioning, where durable and efficient electrode materials are of paramount importance.

KW - Additive manufacturing

KW - Contact arc metal grinding

KW - Fused tungsten carbide

KW - Laser-based directed energy deposition

KW - Metal matrix composites

KW - Thermal cutting

UR - http://www.scopus.com/inward/record.url?scp=105007035870&partnerID=8YFLogxK

U2 - 10.1016/j.wear.2025.206150

DO - 10.1016/j.wear.2025.206150

M3 - Article

AN - SCOPUS:105007035870

VL - 578-579

JO - WEAR

JF - WEAR

SN - 0043-1648

M1 - 206150

ER -