Investigation on cracking behavior of Ni-based coating by laser-induction hybrid cladding

Based on the experiments of laser-induction hybrid cladding by powder feeding, the cracking behavior of Ni-based coating and solidification characteristic in molten pool were investigated. The results indicate that the hybrid cladding is effective to prevent from cracking in Ni-based coating. With the increase of induction energy density, the tensile stress and crack rate decrease obviously. When the induction energy density arrives at 36 J/mm², the free-cracks coating can be achieved. In laser-induction hybrid cladding, the martensite can be eliminated in the heat affected zone and the phase transformation stress is little. Moreover, the molten pool is solidified through two directions such as the coating surface and coating/substrate interface, i.e., firstly the top and bottom in molten pool are solidified, and then the middle in molten pool is solidified. Therefore, in hybrid cladding, the peak value of tensile stress is located in the middle of coating, which is different from that in laser cladding. This distribution status of residual stress is greatly helpful to restrict the cracks of Ni-based coating in laser-induction hybrid cladding.     

激光冲击对E690高强钢激光熔覆修复微观组织的影响

为研究激光冲击对E690高强钢激光熔覆修复层微观组织的影响,选用专用金属粉末对E690高强钢试样预制凹坑进行激光熔覆修复,并使用脉冲激光对激光熔覆层进行冲击强化处理,同时采用扫描电镜、透射电镜和X射线应力分析仪分别对激光冲击前后激光熔覆层的微观组织和表面残余应力进行检测。结果表明:激光熔覆修复后,激光熔覆层组织为等轴晶,熔覆层与E690高强钢基体之间冶金结合良好,其表面残余应力为均匀分布的压应力。经激光冲击后,激光熔覆层截面晶粒得到细化,并观察到大量的形变孪晶,互相平行的孪晶界分割熔覆层粗大晶粒,在激光熔覆层的晶粒细化过程中发挥着重要作用;试样表层位错在{110}滑移面上发生交滑移,在晶界周围形成了位错缠结。经激光冲击后,激光熔覆层冲击区域表面残余压应力数值相较于冲击前提升了1.1倍。     

金属陶瓷复合涂层的激光熔覆与无裂纹的实现

鉴于传统的激光熔覆金属陶瓷复合涂层技术主要存在2方面不足：其一,熔覆效率低,导致大面积熔覆时成本昂贵;其二,由于激光熔覆本身的特点,即快速加热与快速凝固,在激光熔覆过程中,热应力极易诱导熔覆层开裂。基于此,综述了国内外激光熔覆金属陶瓷复合涂层的研究进展,指出其存在的主要问题,并提出了激光感应复合快速熔覆的新方法,即感应预热基材的同时快速激光熔覆。该方法不仅可使熔覆效率大大提高而且获得了无裂纹的金属陶瓷复合涂层。     

Stress evaluation of laser cladding coating with critically refracted longitudinal wave based on cross correlation function

Research on stress evaluation of laser cladding coating with critically refracted longitudinal wave was introduced in this paper. Two critically refracted longitudinal wave transducers with 5 MHz frequency, spacing between which was constant, were employed as signal emitter and receiver. Based on acoustoelastic equation deduction, relationship between the difference in time of flight and tensile stress is obtained. Combing with cross correlation theory, the difference in time of flight between stressed and unstressed critically refracted longitudinal signals was calculated. Results show that stress evaluation is affected by layer interface and anisotropic microstructure of laser cladding coating, precision of stress evaluation of laser cladding coating increases as step length increases until it attains one cycle. In addition, influence of waveform distortion caused by microstructure of laser cladding coating on stress evaluation is discussed. At last, verification test is carried out and the experimental result is well consistent with theoretical result.     

Effects of processing parameters on structure of Ni-based WC composite coatings during laser induction hybrid rapid cladding

The relationships between the processing parameters (i.e. laser specific energy, powder density, preheated temperature of substrate and types of substrate) and the structure characteristics of Ni-based WC composite coatings during laser induction hybrid rapid cladding (LIHRC) were investigated systematically. The results show that laser specific energy, cladding height and contact angle have a linear relation with powder density, as can provide the predictions of laser processing parameters according to the geometrical characteristics of a single laser track (i.e. cladding height, cladding width). Moreover, dilution of composite coating increases with the increasing of laser specific energy and the preheated temperature of substrate, while reduces with the increasing of powder density. The types of substrate also have an important effect on dilution of composite coating, as has a strong dependence on the thermophysical properties of substrate (i.e. melting point, resistivity and permeability).     

Effect of laser energy on the deformation behavior in microscale laser bulge forming

Microscale laser bulge forming is a high strain rate microforming method using high-amplitude shock wave pressure induced by pulsed laser irradiation. The process can serve as a rapidly established and high precision technique to impress microfeatures on thin sheet metals and holds promise of manufacturing complex miniaturized devices. The present paper investigated the forming process using both numerical and experimental methods. The effect of laser energy on microformability of pure copper was discussed in detail. A 3D measuring laser microscope was adopted to measure deformed regions under different laser energy levels. The deformation measurements showed that the experimental and numerical results were in good agreement. With the verified simulation model, the residual stress distribution at different laser energy was predicted and analyzed. The springback was found as a key factor to determine the distribution and magnitude of the compressive residual stress. In addition, the absorbent coating and the surface morphology of the formed samples were observed through the scanning electron microscope. The observation confirmed that the shock forming process was non-thermal attributed to the protection of the absorbent coating.     

短波长化学激光系统反射镜研制

 报道了短波长化学激光系统高反射镜的膜系设计、镀膜材料的选取、反射膜制备技术、基板加工、反射镜性能测试和各种膜系反射镜在强激光辐照下的热畸变和损伤。     

Bonding of glass with femtosecond laser pulses at high repetition rates

We report on the welding of fused silica with ultrashort laser pulses at high repetition rates. Femtosecond laser pulses were focused at the interface of two optically contacted fused silica samples. Due to the nonlinear absorption in the focal volume and heat accumulation of successive pulses, the laser acts as a localized heat source at the focus position. Here, we analyze the influence of the laser and processing parameters on the amount of molten material. Moreover, we determine the achievable breaking stress by a three point bending test. With optimized parameters up to 75% of the breaking stress of the bulk material have been obtained.     

Microstructure and interface interaction in laser induction hybrid cladding of Ni-based coating

Based on the powder feeding laser induction hybrid cladding experiments by means of three different laser and induction energy, the microstructure of Ni-based coating and interface characteristics between the Ni-based coating and steel substrate were investigated. The results show that the hybrid cladding energy including laser and induction energy has an important influence on the formation of the interface and the microstructure of the Ni-based coating characterized by the dendrite. In addition, the laser and induction energy can complement each other. For high hybrid cladding energy, the single phase Fe-Ni-Cr solid solution is formed at the interface between the coating and substrate, while the microhardness of the Ni-based coating decreases. For low hybrid cladding energy, the solid solution phases of Fe-Ni-Cr and Ni-Fe-Cr are respectively obtained on both sides of the interface and microhardness of the Ni-based coating is relatively high. During laser induction hybrid cladding, the metallurgical bond characterized by the white light layer is achieved between the coating and substrate, and the extent of metallurgical reaction can be controlled by adjusting the laser energy and induction energy appropriately.     

面曝光选区激光熔化成形形状精度研究

主要研究面曝光选区激光熔化单层成形时,激光光斑搭接率和电流对形状精度的影响。实验通过控制变量法研究搭接率、曝光时间、电流等工艺参数对激光光斑、熔道、圆环、尖角等成形形状精度的影响。实验结果表明:一定范围内,电流越大,激光光斑更均匀,成形一致性更好;搭接率38.4%能够获得最低的形状误差的熔道;搭接率一定,圆环成形误差随电流的增加而增加;尖角成形误差随着电流增加,呈现先增后减的趋势;搭接率为46.1%、38.4%时,零级衍射带来的形状误差降低。     

磁场辅助激光熔覆制备Ni60CuMoW复合涂层

采用磁场辅助激光熔覆技术,在Q235钢表面制备了Ni60CuMoW复合涂层,借助SEM,EDS 和XRD 等表征手段对涂层进行了微观组织和物相分析,利用维氏硬度计测试了复合涂层截面的显微硬度分布,通过摩擦磨损实验和电化学测试系统研究了复合涂层的磨损性能和耐腐蚀性能。研究结果表明:涂层主要由-Ni,Cu）固溶体、硅化物和硼化物组成,Cr3Si晶粒细化且均匀致密;磁场辅助作用下,激光熔覆涂层平均显微硬度达到913HV0.5,为无磁场辅助涂层的1.5 倍,磨损失重仅为无磁场涂层的36%,自腐蚀电位上升了100 mV,腐蚀电流密度降低了70%,耐磨耐蚀性能得到了显著改善。     

送粉角度对激光熔覆铁基复合涂层形状特征的影响

通过分析激光熔覆过程中光束、粉末和熔池间的作用机理,建立了送粉式激光熔覆材料有效利用率的数学模型,在此基础上推导了送粉角度与工艺参数之间的定量关系式,并计算了不同送粉角度下的熔覆材料有效利用率、熔高和横截面积。结果表明,在熔覆工艺参数不变的条件下,理论计算的熔覆材料有效利用率、熔覆层高度和横截面积均随送粉角度的增加而增大,且均高于实验检测值。激光熔覆过程中,由于粉末烧损和机械损失,使熔覆材料有效利用率、熔高和横截面积随送粉角度变化出现最大值,理想送粉角度为60。     

Study on modes of energy action in laser-induction hybrid cladding

The shape and microstructure in laser-induction hybrid cladding were investigated, in which the cladding material was provided by means of three different methods including the powder feeding, cold pre-placed coating (CPPC) and thermal pre-placed coating (TPPC). Moreover, the modes of energy action in laser-induction hybrid cladding were also studied. The results indicate that the cladding material supplying method has an important influence on the shape and microstructure of coating. The influence is decided by the mode of energy action in laser-induction hybrid cladding. During the TPPC hybrid cladding of Ni-based alloy, the laser and induction heating are mainly performed on coating. During the CPPC hybrid cladding of Ni-based alloy, the laser and induction heating are mainly performed on coating and substrate surface, respectively. In powder feeding hybrid cladding, a part of laser is absorbed by the powder particles directly, while the other part of laser penetrating powder cloud radiates on the molten pool. Meanwhile, the induction heating is entirely performed on the substrate. In addition, the wetting property on the interface is improved and the metallurgical bond between the coating and substrate is much easier to form. Therefore, the powder feeding laser-induction hybrid cladding has the highest cladding efficiency and the best bond property among three hybrid cladding methods.     

Numerical simulation of temperature distribution and TiC growth kinetics for high power laser clad TiC/NiCrBSiC composite coatings

A three dimensional model was proposed to simulate high power laser clad TiC/NiCrBSiC composite coatings on Ti6Al4V alloys. The temperature distribution, temperature curves on different nodes, three dimensional shape and size of TiC melting region, molten pool and heat affected zone (HAZ) of the substrate were obtained. To have a clear physical insight into the phase transformation and microstructure evolution in the coatings during laser cladding process, a theoretical kinetic analysis was performed to elucidate the nucleation, growth velocity, and size of TiC particles on the basis of simulated temperature curves of the molten pool. A good quality TiC/NiCrBSiC composite coating with low dilution rate and excellent metallurgical bond was fabricated under optimal processing parameters using powder mixture of TiC and NiCrBSiC as clad material and cuboid of Ti6Al4V alloys as substrate. To validate the reliability of the proposed model, the theoretical results were compared with the microstructure of the coatings. It shows that these theoretical results are in excellent agreement with the experiment cases.     

Investigation of temperature and stress fields in laser cladded coatings

Temporal and spatial distributions of temperature and strain-stress have been modelled and investigated experimentally for the laser cladding process. The model corresponded to experimental conditions where the multilayer protective coatings were prepared by direct laser cladding of stellite SF6 powder on X10Cr13 chromium steel by means of a 1.2 kW CO₂ laser. For calculations the effect of base preheating, temperature dependent material properties, and also influence of time-break between cladding of the consecutive layers were taken into account. The calculated temperature fields indicated good bonding of the substrate and coating, which was in agreement with the micro-analytical test results. A decrease of the number of microcracks in the coating with an increase of substrate preheating temperature was concluded from stress calculations and confirmed in the experiment. Moreover, an increase of the cracking susceptibility with an increase of the time delay between cladding of the consecutive layers was evidenced by modelling. The best technological results were obtained for the case of single-layer coatings prepared on a preheated substrate and for higher coating thickness required the processing of consecutive layers with a possibly short time delay is advisable due to effective usage of laser beam energy for preheating and lower temperature gradients.     

煤岩变质变形作用的谱学研究

为了探讨不同变质程度煤在不同变形机制和变形强度影响下的结构成分演化,该文对淮北煤田经历不同变质变形作用的构造煤样品进行了傅里叶变换红外光谱(FTIR)和激光Raman光谱的测试和分析.FTIR显示,变质和变形作用对大分子结构的降解和缩聚过程有着不同程度的影响;激光Raman光谱显示,变形作用导致大分子结构中次生结构缺陷的产生,变质作用对次生结构缺陷和芳族总量也有一定的影响.综合研究表明:韧性变形将应力作用转换成应变能,对降解和缩聚产生明显的影响,而脆性变形将应力作用转换成热能,促进降解的进行,对缩聚作用的影响较小.低变质阶段煤岩以降解作用为主,高变质阶段则以缩聚作用为主.在变质变形作用的影响下,脱落的小分子优先补充嵌入大分子结构的次生结构缺陷中或残留的芳环缩聚形成芳族结构,从而提高煤岩结构的稳定性,且韧性变形比脆性变形更容易导致次生结构缺陷的形成.     

Characterization of dilution action in laser-induction hybrid cladding

Based on an experimental study of laser-induction hybrid cladding by powder feeding, the dilution action and elemental composition distribution were investigated in detail. The results indicate that, compared with individual laser cladding, by using laser-induction hybrid cladding it is easier to form a metallurgical bonding coating and the change range of dilution is much larger. Moreover, at the bottom of molten region, the morphology exhibits nearly a straight line. The processing parameters have great influence on dilution in hybrid cladding. With the increase of scanning speed, the tendency of dilution presents a U-shaped profile, i.e., the middle dilution is much less than those of two ends. The dilution increases with the induction energy. Furthermore, the bigger the dilution, the more uniform is the elemental composition throughout coating. In laser-induction hybrid cladding, the microstructure of low dilution coating is relatively fine due to the low hybrid cladding energy. By adjusting the laser energy and induction energy appropriately, i.e., high induction energy—low laser energy, the low dilution coating with fine microstructure and good mechanical properties can be achieved.     

A study of TiB2/TiB gradient coating by laser cladding on titanium alloy

TiB₂/TiB gradient coating has been fabricated by a laser cladding technique on the surface of a Ti–6Al–4V substrate using TiB₂ powder as the cladding material. The microstructure and mechanical properties of the gradient coating were analyzed by SEM, EPMA, XRD, TEM and an instrument to measure hardness. With the increasing distance from the coating surface, the content of TiB₂ particles gradually decreased, but the content of TiB short fibers gradually increased. Meanwhile, the micro-hardness and the elastic modulus of the TiB₂/TiB coating showed a gradient decreasing trend, but the fracture toughness showed a gradient increasing trend. The fracture toughness of the TiB₂/TiB coating between the center and the bottom was improved, primarily due to the debonding of TiB₂ particles and the high fracture of TiB short fibers, and the fracture position of TiB short fiber can be moved to an adjacent position. However, the debonding of TiB₂ particles was difficult to achieve at the surface of the TiB₂/TiB coating.     

Laser induction hybrid rapid cladding of WC particles reinforced NiCrBSi composite coatings

In order to investigate the microstructure characteristics and properties of Ni-based WC composite coatings containing a relatively large amount of WC particles by laser induction hybrid rapid cladding (LIHRC) and compare to the individual laser cladding without preheating, Ni60A + 35 wt.% WC composite coatings are deposited on A3 steel plates by LIHRC and the individual laser cladding without preheating. The composite coating produced by the individual laser cladding without preheating exhibits many cracks and pores, while the smooth composite coating without cracks and pores is obtained by LIHRC. Moreover, the cast WC particles take on the similar dissolution characteristics in Ni60A + 35 wt.% WC composite coatings by LIHRC and the individual laser cladding without preheating. Namely, the completely dissolved WC particles interact with Ni-based alloy solvent to precipitate the blocky and herringbone carbides, while the partially dissolved WC particles still preserve the primary lamellar eutectic structure. A few WC particles are split at the interface of WC and W₂C, and then interact with Ni-based alloy solvent to precipitate the lamellar carbides. Compared with the individual laser cladding without preheating, LIHRC has the relatively lower temperature gradient and the relatively higher laser scanning speed. Therefore, LIHRC can produce the crack-free composite coating with relatively higher microhardness and relatively more homogeneous distribution of WC particles and is successfully applied to strengthen the corrugated roller, showing that LIHRC process has a higher efficiency and good cladding quality.     

激光冲击强化提高K403铸造高温合金疲劳性能

采用YLSS-M60U型高能Nd:YAG激光器,对发动机高压涡轮叶片材料K403/K3铸造高温合金试片进行激光冲击强化处理,强化工艺参数为:激光能量3J,光斑直径2.6mm,脉宽20ns,波长1064nm,吸收保护层为铝箔,约束层为水,搭接率50%,冲击3次。强化后,在420MPa应力水平下进行了室温高周振动疲劳测试,并进行了扫描电镜观察和X射线衍射仪物相分析。研究结果表明:激光冲击强化后,试片疲劳寿命是原始状态试片寿命的2.4倍,激光冲击强化的强冲击波作用使金属发生高应变率塑性变形,以及随之产生的较大较深残余压应力,是金属疲劳性能提高的主要原因。