The fusion of surface-modified steel with tungsten carbide (WC) and NiCrBSi powder through laser metal deposition has emerged as a formidable strategy for fortifying components against wear and corrosion in extreme operating environments. Meticulous selection of WC content, innovative pre-alloying techniques, and precise control of laser metal deposition profoundly influence the mechanical properties and microstructural evolution of WC-NiCrBSi coatings applied to surface-enriched commercial alloy steel (805M2, 832M13, and 827M40). These tailored coatings exhibit exceptional resilience, ideal for harsh industrial settings in Oil and gas drilling, petrochemical, and Mining sectors. Advanced materials testing techniques, including scanning electron microscopy, light optical microscopies, and microhardness testing, unveil the innate hardness attributes, with findings highlighting the unassailable fortitude of the Mixed matrix layer's side face. The amalgamation of these testing methodologies with laser metal deposition promises an unparalleled path to extend the operational lifespan of critical components in challenging working conditions. The research horizon for WC-NiCrBSi coatings remains broad, with the potential to enhance durability, operational efficiency, and cost-effectiveness across diverse applications.

Lightweight component design is effectively achievable through the sandwich structures, many past research studies in the aerospace and racing sectors (since 1920s) has proven it. To extend their application into automotive and other transport industries, the manufacturing cycle times must be reduced. This can be achieved by thermoplastic sandwich materials of continuous fibre-reinforced thermoplastic (CFRTP) cover layers and thermoplastic honeycomb cores. To widespread the application of flat thermoplastic-based sandwich panels into complex parts, a novel forming technology was developed by the Fraunhofer Institute of Microstructure of Materials and Systems (IMWS). For an increase in reproducibility of the sandwich component production and a decrease in manufacturing defects, numerical modelling methods and experimental validation are needed. The finite element (FE) modelling of this thermoforming process is a thermo-mechanical assignment with all three: material, geometry, and boundary non-linearities. In the scope of this work, the material behavior of different sandwich components (cover layers, honeycomb core, interface) under thermo-mechanical loads is characterized in detail, and a complex numerical model is developed to describe the thermoforming process of thermoplastic-based sandwich laminate. The critical forming condition like wrinkling that occurs due to friction in a sandwich or poor intra-ply shear in cross-ply studied, validated, and optimized. A thermoplastic sandwich made of polypropylene (PP) honeycomb core and polypropylene glass fibre (PP/GF) cross-ply as cover layers was used for this study, and numerical modelling was executed in LS-DYNA software.