Colmonoy Hardsurfacing

Naval nuclear reactor plant components can require specialized hardsurfacing metals that are able to withstand harsh operating environments with minimal maintenance over the life of the ship.  One such material is Colmonoy 5, which is used in applications that require metal-on-metal wear.  Colmonoy 5 is a superior material when it is deposited and machined correctly.  However, the process window to a successful deposition is narrow, time consuming, and heavily dependent on a limited pool of skilled labor.  
Hybrid machining with subtractive and additive methods provides an opportunity to revolutionize the way components with hardsurfacing are fabricated.  By allowing a CNC machine and Direct Energy Deposited (DED) laser to work in a single set-up and transition between each other, a fabricator can go from bar stock to a final part using minimal set-ups and automation that can be dialed in to consistently hit the narrow process controls, eliminating reliance on skilled labor and human error.
Information is sought on technologies to qualify hybrid machining to hardsurface parts with Colmonoy 5 powder.  Information on technologies that can enable more effective and cost-efficient manufacturing improving schedule, enhancing quality of components, and reducing the reliance on skilled labor is of interest.
Requirements to qualify hybrid machining as the future for fabricating hardsurfaced parts include:
•    Hardsurfacing applied through additive manufacturing with minimal human intervention or monitoring
•    Machining takes place before and after hardsurfacing without removal from the machine
•    Hybrid machine uses laser DED with powder based Colmonoy 5 filler metal
•    Hardsurfacing can be applied to:
o    Inconel 600 – MIL-DTL-23229, Condition D, Type II or III
o    Inconel 718 – MIL-DTL-24492, Condition 1750/AH, Composition L, Type II
o    Stainless Steel 348 – MIL-DTL-23195, Condition A, Composition 348, Type II or III
•    Meets a minimum hardness value of 42 Rockwell C per ASTM E18 hardness testing (some sealing surface applications require a hardness of 50 HRC).
•    Must have good bond or fusion with the base material
•    Final surface passes liquid penetrant inspection
o    No linear indications
o    Minimal rounded indications (in each sq inch, less than 20 indications measured between 1/64” and 1/32”) - some critical applications require essentially zero surface indications