ISSN 0253-2778

CN 34-1054/N

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Study on the effect of laser cladding Ni35A + TiC composite cladding morphology and forming efficiency

  • School of Mechanical and Automotive Engineering, Fujian University of Technology, Fuzhou 350118, China

Cite this:
https://doi.org/10.3969/j.issn.0253-2778.2020.06.001
  • Received Date: 16 September 2019
  • Accepted Date: 30 April 2020
  • Rev Recd Date: 30 April 2020
  • Publish Date: 30 June 2020
    Abstract

  • Abstract

    In order to investigate the influence of laser cladding process parameters and TiC powder ratio on the cladding morphology and forming efficiency of composite materials ，improve the cladding morphology in terms of surface quality and substrate melting depth, and improve the forming efficiency of composite materials, the central composite design module of the response surface methodology(RSM) was adopted to analyze the effects of laser power, scanning speed, gas flow and TiC powder ratio on the morphology of composite claddings. A mathematical model was established between process parameters and TiC powder ratio, and composite cladding efficiency and substrate melting depth. The accuracy of the model was verified by variance analysis. Results show that, the effect of gas flow on the morphology of composite claddings is not significant. The cladding morphology is remarkably improved by increasing laser power, decreasing scanning speed and reducing TiC powder ratio. The scanning speed and TiC powder ratio have the most remarkable effects on the cladding efficiency. Therefore, reducing the TiC powder ratio and increasing the scanning speed appropriately could improve the cladding efficiency. Laser power has the most significant influence on the melting depth of the substrate and shows a secondary positive correlation, and the remaining parameters show a negative linear correlation. The analysis reveals that different materials’ requirement for cladding energy is the most important cause of the difference in the cladding efficiency and the morphology of composite materials with different compositions. With the maximum cladding efficiency and the minimum melting depth of the substrate as the goal of optimization, a comparison was made between the predicted and test values and found that the error rate of the cladding efficiency and that of the melting depth of the substrate were 3.450% and 5.386% respectively. This research provides a theoretical guidance for composite materials in improving the cladding morphology, and for predicting and controlling the cladding efficiency.

    Abstract

    In order to investigate the influence of laser cladding process parameters and TiC powder ratio on the cladding morphology and forming efficiency of composite materials ，improve the cladding morphology in terms of surface quality and substrate melting depth, and improve the forming efficiency of composite materials, the central composite design module of the response surface methodology(RSM) was adopted to analyze the effects of laser power, scanning speed, gas flow and TiC powder ratio on the morphology of composite claddings. A mathematical model was established between process parameters and TiC powder ratio, and composite cladding efficiency and substrate melting depth. The accuracy of the model was verified by variance analysis. Results show that, the effect of gas flow on the morphology of composite claddings is not significant. The cladding morphology is remarkably improved by increasing laser power, decreasing scanning speed and reducing TiC powder ratio. The scanning speed and TiC powder ratio have the most remarkable effects on the cladding efficiency. Therefore, reducing the TiC powder ratio and increasing the scanning speed appropriately could improve the cladding efficiency. Laser power has the most significant influence on the melting depth of the substrate and shows a secondary positive correlation, and the remaining parameters show a negative linear correlation. The analysis reveals that different materials’ requirement for cladding energy is the most important cause of the difference in the cladding efficiency and the morphology of composite materials with different compositions. With the maximum cladding efficiency and the minimum melting depth of the substrate as the goal of optimization, a comparison was made between the predicted and test values and found that the error rate of the cladding efficiency and that of the melting depth of the substrate were 3.450% and 5.386% respectively. This research provides a theoretical guidance for composite materials in improving the cladding morphology, and for predicting and controlling the cladding efficiency.
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    • References(23)
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    GONG X, WANG J, FENG H. Lateral powder transport model with Gaussian distribution in laser cladding[J]. The International Journal of Advanced Manufacturing Technology, 2019, 102: 3747-3756.
    [2]
    LU Y, HUANG G, WANG Y, et al. Crack-free Fe-based amorphous coating synthesized by laser cladding[J]. Materials Letters, 2018, 210: 46-50.
    [3]
    CHAKRABORTY S S, DUTTA S. Estimation of dilution in laser cladding based on energy balance approach using regression analysis[J]. Sādhanā, 2019, 44: 150.
    [4]
    ZHANG Z, KOVACEVIC R. Laser cladding of iron-based erosion resistant metal matrix composites[J]. Journal of Manufacturing Processes, 2019, 38: 63-75.
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    BAX B, RAJPUT R, KELLET R, et al. Systematic evaluation of process parameter maps for laser cladding and directed energy deposition[J]. Additive Manufacturing, 2018, 21: 487-494.
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    FERNANDEZ E, CADENAS M, GONZALEZ R, et al. Wear behaviour of laser clad NiCrBSi coating[J]. Wear, 2005, 259: 870-875.
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    ZHAI L L, BAN C Y, ZHANG J W. Microstructure, microhardness and corrosion resistance of NiCrBSi coatings under electromagnetic field auxiliary laser cladding[J]. Surface and Coatings Technology, 2019, 358: 531-538.
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    SHEN M Y, TIAN X J, LIU D, et al. Microstructure and fracture behavior of TiC particles reinforced Inconel 625 composites prepared by laser additive manufacturing[J]. Journal of Alloys and Compounds, 2018, 734: 188-195.
    [13]
    BAKKAR A, AHMED M M Z, ALALEH N A, et al. Microstructure, wear, and corrosion characterization of high TiC content Inconel 625 matrix composites[J]. Journal of Materials Research and Technology, 2019, 8(1): 1102-1110.
    [14]
    MAKAROV A V, SOBOLEVA N N, MALYGINA I Y, et al. The tribological performances of a NiCrBSi-TiC laser-clad composite coating under abrasion and sliding friction[J]. Diagnostics, Resource and Mechanics of Materials and Structures, 2015(3): 83-97.
    [15]
    WEN P, FENG Z, ZHENG S. Formation quality optimization of laser hot wire cladding for repairing martensite precipitation hardening stainless steel[J]. Optics & Laser Technology, 2015, 65: 180-188.
    [16]
    RAGAVENDRAN M, CHANDRASEKHAR N, RAVIKUMAR R, et al. Optimization of hybrid laser-TIG welding of 316LN steel using response surface methodology (RSM)[J]. Optics and Lasers in Engineering, 2017, 94: 27-36.
    [17]
    SAFEEN W, HUSSAIN S, WASIM A, et al. Predicting the tensile strength, impact toughness, and hardness of friction stir-welded AA6061-T6 using response surface methodology[J]. The International Journal of Advanced Manufacturing Technology, 2016, 87: 1765-1781.
    [18]
    ALTARAZI S, HIJAZI L, KAISER E. Process parameters optimization for multiple-inputs-multiple-outputs pulsed green laser welding via response surface methodology[C]// 2016 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM).Piscataway: IEEE, 2016: 1041-1045.
    [19]
    CUI C, GUO Z, WANG H, et al. In situ TiC particles reinforced grey cast iron composite fabricated by laser cladding of Ni-Ti-C system[J]. Journal of Materials Processing Technology, 2007, 183: 380-385.
    [20]
    EMAMIAN A, CORBIN S F, KHAJEPOUR A. Effect of laser cladding process parameters on clad quality and in-situ formed microstructure of Fe-TiC composite coatings[J]. Surface and Coatings Technology, 2010, 205(7): 2007-2015.
    [21]
    LEI Y, SUN R, TANG Y, et al. Numerical simulation of temperature distribution and TiC growth kinetics for high power laser clad TiC/NiCrBSiC composite coatings[J]. Optics & Laser Technology, 2012, 44(4): 1141-1147.
    [22]
    MUVVALA G, KARMAKAR D P, NATH A K. Online assessment of TiC decomposition in laser cladding of metal matrix composite coating[J]. Materials & Design, 2017, 121: 310-320.
    [23]
    PRZYBYLOWICZ J, KUSINSKI J. Structure of laser cladded tungsten carbide composite coatings[J]. Journal of Materials Processing Technology, 2001, 109: 154-160.)
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    [1]
    GONG X, WANG J, FENG H. Lateral powder transport model with Gaussian distribution in laser cladding[J]. The International Journal of Advanced Manufacturing Technology, 2019, 102: 3747-3756.
    [2]
    LU Y, HUANG G, WANG Y, et al. Crack-free Fe-based amorphous coating synthesized by laser cladding[J]. Materials Letters, 2018, 210: 46-50.
    [3]
    CHAKRABORTY S S, DUTTA S. Estimation of dilution in laser cladding based on energy balance approach using regression analysis[J]. Sādhanā, 2019, 44: 150.
    [4]
    ZHANG Z, KOVACEVIC R. Laser cladding of iron-based erosion resistant metal matrix composites[J]. Journal of Manufacturing Processes, 2019, 38: 63-75.
    [5]
    BAX B, RAJPUT R, KELLET R, et al. Systematic evaluation of process parameter maps for laser cladding and directed energy deposition[J]. Additive Manufacturing, 2018, 21: 487-494.
    [6]
    FERNANDEZ E, CADENAS M, GONZALEZ R, et al. Wear behaviour of laser clad NiCrBSi coating[J]. Wear, 2005, 259: 870-875.
    [7]
    RIO G D, GARRIDO M A, FERNANDEZ J E, et al. Influence of the deposition techniques on the mechanical properties and microstructure of NiCrBSi coatings[J]. Journal of Materials Processing Technology, 2008, 204: 304-312.
    [8]
    ZHAI L L, BAN C Y, ZHANG J W. Microstructure, microhardness and corrosion resistance of NiCrBSi coatings under electromagnetic field auxiliary laser cladding[J]. Surface and Coatings Technology, 2019, 358: 531-538.
    [9]
    WANG X H, ZHANG M, LIU X M, et al. Microstructure and wear properties of TiC/FeCrBSi surface composite coating prepared by laser cladding[J]. Surface and Coatings Technology, 2008, 202(15): 3600-3606.
    [10]
    BAI H, ZHONG L, SHANG Z, et al. Microstructure and mechanical properties of TiC-Fe surface gradient coating on a pure titanium substrate prepared in situ[J]. Journal of Alloys and Compounds, 2019, 771: 406-417.
    [11]
    GU D, ZHANG H, DAI D, et al. Laser additive manufacturing of nano-TiC reinforced Ni-based nanocomposites with tailored microstructure and performance[J]. Composites Part B: Engineering, 2019, 163: 585-597.
    [12]
    SHEN M Y, TIAN X J, LIU D, et al. Microstructure and fracture behavior of TiC particles reinforced Inconel 625 composites prepared by laser additive manufacturing[J]. Journal of Alloys and Compounds, 2018, 734: 188-195.
    [13]
    BAKKAR A, AHMED M M Z, ALALEH N A, et al. Microstructure, wear, and corrosion characterization of high TiC content Inconel 625 matrix composites[J]. Journal of Materials Research and Technology, 2019, 8(1): 1102-1110.
    [14]
    MAKAROV A V, SOBOLEVA N N, MALYGINA I Y, et al. The tribological performances of a NiCrBSi-TiC laser-clad composite coating under abrasion and sliding friction[J]. Diagnostics, Resource and Mechanics of Materials and Structures, 2015(3): 83-97.
    [15]
    WEN P, FENG Z, ZHENG S. Formation quality optimization of laser hot wire cladding for repairing martensite precipitation hardening stainless steel[J]. Optics & Laser Technology, 2015, 65: 180-188.
    [16]
    RAGAVENDRAN M, CHANDRASEKHAR N, RAVIKUMAR R, et al. Optimization of hybrid laser-TIG welding of 316LN steel using response surface methodology (RSM)[J]. Optics and Lasers in Engineering, 2017, 94: 27-36.
    [17]
    SAFEEN W, HUSSAIN S, WASIM A, et al. Predicting the tensile strength, impact toughness, and hardness of friction stir-welded AA6061-T6 using response surface methodology[J]. The International Journal of Advanced Manufacturing Technology, 2016, 87: 1765-1781.
    [18]
    ALTARAZI S, HIJAZI L, KAISER E. Process parameters optimization for multiple-inputs-multiple-outputs pulsed green laser welding via response surface methodology[C]// 2016 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM).Piscataway: IEEE, 2016: 1041-1045.
    [19]
    CUI C, GUO Z, WANG H, et al. In situ TiC particles reinforced grey cast iron composite fabricated by laser cladding of Ni-Ti-C system[J]. Journal of Materials Processing Technology, 2007, 183: 380-385.
    [20]
    EMAMIAN A, CORBIN S F, KHAJEPOUR A. Effect of laser cladding process parameters on clad quality and in-situ formed microstructure of Fe-TiC composite coatings[J]. Surface and Coatings Technology, 2010, 205(7): 2007-2015.
    [21]
    LEI Y, SUN R, TANG Y, et al. Numerical simulation of temperature distribution and TiC growth kinetics for high power laser clad TiC/NiCrBSiC composite coatings[J]. Optics & Laser Technology, 2012, 44(4): 1141-1147.
    [22]
    MUVVALA G, KARMAKAR D P, NATH A K. Online assessment of TiC decomposition in laser cladding of metal matrix composite coating[J]. Materials & Design, 2017, 121: 310-320.
    [23]
    PRZYBYLOWICZ J, KUSINSKI J. Structure of laser cladded tungsten carbide composite coatings[J]. Journal of Materials Processing Technology, 2001, 109: 154-160.)
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