Mass manufacturing cobalt-free hardmetals
Cobalt is a naturally occurring element typically used as a metallic binder material for cemented tungsten carbide. While a critical component in items such as lithium-ion rechargeable batteries, Cobalt has also been linked with negative respiratory and dermal side effects, particularly to those who are mining it. The mining of Cobalt also poses environmental issues, such as increased radioactivity levels and polluted rivers and drinking water.
The ARL has therefore been investigating a replacement for Cobalt, culminating in the development of a patented cobalt-free hardmetal material that uses a novel iron-based nano material as its matrix.
Once the material had been developed, the U.S. Army Contracting Command tasked Desktop Metal with providing a cost-effective, high volume process able to print the novel hardmetals, on behalf of U.S. Army Research Laboratory to the National Center for Manufacturing Sciences (NCMS) and the Advanced Manufacturing, Materials and Processes (AMMP) consortium.
During the project, Desktop Metal will develop a feedstock and binder system for the cobalt-free hardmetal. Without the use of tooling, the firm’s SPJ process will print the novel hardmetals into complex, net, or near-net shaped parts. The goal of the project is to print at least 200,000 parts per day from a single machine.
Desktop Metal will also deliver a cost analysis to step up its SPJ technology for the manufacture of at least 500,000 prototype parts. The company believes its SJP process will “lead the development” of a dual-use technology suitable to various commercial and DoD applications.