Hybrid cutting blades for the production of secondary fuels by waste

In times of unstable supply security and climate protection, only a balanced energy mix will keep German industry operational. This is why high-quality waste-derived fuels are playing an increasingly important role in the energy transition as a resource-saving energy source. They are based on the shredding of household and bulky waste in recycling plants, whereby their efficiency depends on the quality of the granulate. The multiple cutting tools used are exposed to high loads due to the heterogeneous waste. Conventional knives therefore wear out quickly and limit the throughput of those alternative fuels.
To improve the circular economy, this use case study investigates both increasing the durability of the blades and developing a system to reduce metallic waste. The hybrid blades for the stator and rotor each consist of a conventionally manufactured and reusable carrier on the installation side. The blade geometry is produced close to the final shape using additive manufacturing, Powder Bed Fusion by Electron Beam (PBF-EB/M), made from a difficult-to-machine, hard and highly wear-resistant material. A specially developed adhesive ensures a removable bond between the substrate and the cutting edges. In addition to extensive material characterization, the study includes a real-life practical test.