The Recycling Process and Powderization Technology of Stellite 6 Scrap: A Thermodynamic and Heat Transfer Analysis

Co-Cr alloys are widely used in cutting tools and turbine components due to their high strength and resistance against wear and corrosion. However, scrap generated during hardfacing is often discarded due to impurities and oxidation, and research on its recycling remains limited. This study aimed to optimize the recycling process of Stellite 6 scrap to reduce waste and minimize costs while maintaining material quality. Melting, casting, and powdering processes were designed using HSC Chemistry, FactSage, and COMSOL Multiphysics, with optimization of key parameters such as the crucible material and temperature control. The recycled alloy and powder were analyzed using X-ray fluorescence analysis, inductively coupled plasma optical emission spectroscopy, and X-ray diffractometry, showing mechanical and chemical properties comparable to commercial Stellite 6. The Co and Cr contents were maintained, with a slight increase in Fe. These findings demonstrate the potential for producing high-quality recycled Stellite 6 materials, contributing to the sustainable utilization of metal resources in high-performance applications.