Coating thickness affects surface stress measurement of brush electro-plating nickel coating using Rayleigh wave approach

A surface ultrasonic wave approach was presented for measuring surface stress of brush electro-plating nickel coating specimen, and the influence of coating thickness on surface stress measurement was discussed. In this research, two Rayleigh wave transducers with 5 MHz frequency were employed to collect Rayleigh wave signals of coating specimen with different static tensile stresses and different coating thickness. The difference in time of flight between two Rayleigh wave signals was determined based on normalized cross correlation function. The influence of stress on propagation velocity of Rayleigh wave and the relationship between the difference in time of flight and tensile stress that corresponded to different coating thickness were discussed. Results indicate that inhomogeneous deformation of coating affects the relationship between the difference in time of flight and tensile stress, velocity of Rayleigh wave propagating in coating specimen increases with coating thickness increasing, and the variation rate reduces of difference in time of flight with tensile stress increasing as coating thickness increases.     

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.     

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.     

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.     

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。     

碳化钨对激光熔覆高熵合金的影响

为了获得高性能的涂层材料,采用激光熔覆的方法,在Q235钢基体上制备了FeSiCrCoMo高熵合金涂层,并研究了WC对高熵合金涂层的组织和性能的影响。通过金相、X射线衍射、扫描电镜、硬度计、磨损试验机分别研究了添加WC前后涂层的微观形貌、相结构、硬度及磨损性能。结果表明:高熵合金FeSiCrCoMo涂层组织为粗大枝状晶,主要由BCC相和金属间化合物构成,添加WC后,涂层中形成了致密细小的胞状晶,同时BCC相增多,金属间化合物明显减少;添加WC后涂层的硬度明显增强,平均硬度提升了23%,涂层表面平均硬度达到了687HV0.2;WC的添加使得涂层的摩擦系数减小,磨损率减小,耐磨性能提高。     

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。     

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.     

Numerical research on effect of overlap ratio on thermal-stress behaviors of the high-speed laser cladding coating

High-speed laser cladding technology, a kind of surface technology to improve the wear-resistance and corrosion-resistance of mechanical parts, has the characterizations of fast scan speed, high powder utilization rate, and high cladding efficiency. However, its thermal-stress evolution process is very complex, which has a great influence on the residual stress and deformation. In the paper, the numerical models for the high-speed laser cladding coatings with overlap ratios of 10%,30%, and 50% are developed to investigate the influence rules of overlap ratio on the thermal-stress evolution, as well as the residual stresses and deformations. Results show that the heat accumulation can reheat and preheat the adjacent track coating and substrate, resulting in stress release of the previous track coating and decreased longitudinal stress peak of the next track coating. With the overlap ratio increasing, the heat accumulation and the corresponding maximum residual stress position tend to locate in the center of the cladding coating, where the coating has a high crack susceptibility. For a small overlap ratio of 10%, there are abrupt stress changes from tensile stress to compressive stress at the lap joint, due to insufficient input energy in the position. Increasing the overlap ratio can alleviate the abrupt stress change and reduce the residual deformation but increase the average residual stress and enlarge the hardening depth. This study reveals the mechanism of thermal-stress evolution, and provides a theoretical basis for improving the coating quality.     

Numerical and experimental analysis of the critically refracted longitudinal beam

The critically refracted longitudinal (L_CR) wave can be used in numerous non-destructive testing (NDT) applications, such as characterization of surface geometric aspects, subsurface defect detection and mostly for residual stress measurement. However, very few works characterize the associated ultrasonic beam. This paper deals with characterization of the L_CR beam profile both numerically and experimentally in order to optimize the incident angle choice in order to have sufficient energy in the experimental signal. The simulations are performed in time and frequency domains concerning solid elastic, homogenous and isotropic materials taking into account the liquid–solid interaction of the excitation by a water-coupled transducer. In the obtained results all components of the refracted acoustical field are demonstrated, as well as energy distributions of L_CR wave obtained with different incident angles.     

Comparative study of microstructural characteristics of electrospark and Nd:YAG laser epitaxially growing coatings

As low-heat input welding processes, electrospark deposition and pulsed Nd:YAG laser cladding can be commonly used to prepare epitaxially growing coatings. However, these two processes have quite different characteristics in the energy input, the amount of materials involved, and the temperature gradient, and hence might result in dissimilar microstructural characteristics. In this paper, a comparative study has been made between microstructural characteristics in epitaxial growth coatings prepared by electrospark deposition and pulsed Nd:YAG laser cladding. Some interesting results have been achieved. Firstly, epitaxial growth coatings can be commonly achieved by these two techniques. Secondly, microstructural morphologies of these two epitaxial growth coatings are obviously different, cellular columnar structure prevails in the electrospark coating while columnar dendritic structure occupies most of the laser coating thickness, more importantly, electrospark coating remains fully columnar in the whole layer whereas laser coating tends to change from columnar to equiaxed at the top of the layer. Thirdly, electrospark coating possesses finer and more homogeneous microstructure than laser coating.     

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。     

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。     

Bolt axial stress measurement based on a mode-converted ultrasound method using an electromagnetic acoustic transducer

A method is proposed to measure the stress on a tightened bolt using an electromagnetic acoustic transducer (EMAT). A shear wave is generated by the EMAT, and a longitudinal wave is obtained from the reflection of the shear wave due to the mode conversion. The ray paths of the longitudinal and the shear wave are analyzed, and the relationship between the bolt axial stress and the ratio of time of flight between two mode waves is then formulated. Based on the above outcomes, an EMAT is developed to measure the bolt axial stress without loosening the bolt, which is required in the conventional EMAT test method. The experimental results from the measurement of the bolt tension show that the shear and the mode-converted longitudinal waves can be received successfully, and the ratio of the times of flight of the shear and the mode-converted longitudinal waves is linearly proportional to the bolt axial tension. The non-contact characteristic of EMAT eliminates the effect of the couplant and also makes the measurement more convenient than the measurement performed using the piezoelectric transducer. This method provides a promising way to measure the stress on tightened bolts.     

Experimental study on the surface stress measurement with Rayleigh wave detection technique

In this paper, experimental study on the surface stress measurement of a metallic material based on the Rayleigh wave acoustoelastic theory is introduced. A Rayleigh wave acoustoelastic formula deduced by Husson is optimized to estimate the surface stress of the material. Two micro Rayleigh wave transducers with 5 MHz frequency one of which is used for acoustic pulse emitter and another for receiver are used to determine the time of flight of Rayleigh wave propagating in a certain distance along the surface of the material. The difference in time of flight between two ultrasonic signals obtained in stressed and unstressed object surface is identified by the digital correlation method. A specimen made of Q235 steel and applied with tensile load is used for calibration to obtain the acoustoelastic coefficients of Q235 steel. Furthermore, some principal factors which may result in errors in the experiment are discussed and some measurements are proposed to prevent these errors. Finally the surface stress of a cantilever beam is detected by the Rayleigh wave acoustoelastic technique and the experimental result is well compared with the theoretical value.     

Si,Al对激光熔覆MoFeCrTiW高熵合金涂层组织性能的影响

为了提高材料表面的耐磨性和高温抗氧化性,利用激光熔覆技术在Q235钢表面制备了MoFeCrTiW高熵合金涂层,并采用X射线衍射仪(XRD)、扫描电镜(SEM)和磨损试验机等研究了Si,Al添加对高熵合金涂层组织、相结构、耐磨性和高温抗氧化性能的影响。结果表明:激光熔覆MoFeCrTiW高熵合金涂层组织为等轴晶,单独添加等物质的量的Si或Al时,涂层分别为共晶组织或树枝晶,同时添加等物质的量的Si和Al时,涂层组织为细小的等轴晶。各高熵合金涂层的主体相均为BCC相,随着Si,Al的添加,BCC相的晶格常数减小。添加等物质的量的Al有助于抑制涂层中金属间化合物的形成,使涂层耐磨性降低;添加等物质的量的Si则会形成含Si的金属间化合物和一些未知相,提高涂层耐磨性。激光熔覆MoFeCrTiW高熵合金涂层在800℃的抗氧化性较高,Si、Al的添加可使涂层的高温抗氧化性进一步提高。     

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.     

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).     

Non-contact sound speed measurement by optical probing of beam deflection due to sound wave

We report a non-contact and non-invasive method of sound speed measurement by optical probing of deflected laser beam due to normally incident degenerated shock wave. In this study the shock wave from an exploding wire was degenerated to an ordinary sound wave at the distance exceeding 0.23 m. Temporal resolution of the deflected beam signal was improved by passing through an adequate electronic high-pass filter, as a result we obtained a better temporal resolution than that of the acoustic pressure detection by PZT transducer in terms of rising time. The spatial resolution was improved by passing the refracted beam signal into the edge of focusing lens to make a larger deflection angle. Sound speed was calculated by monitoring the time of flight of transient deflected signal at the predetermined position. Sound speed has been measured in air, distilled water and acryl, agreed well with the published values. The sound speed measured in the solution of glycerin, magnesium sulfate (MgSO4), and dimethylformamide with various mole fractions also agrees within 3% of relative error with those measured in the present work by ultrasonic pulse echo method. The results suggest that the method proposed is to be reliable and reproducible.     

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.