New 3D model for accurate prediction of thermal and microstructure evolution of laser powder cladding of Ti6Al4V alloy

Abstract

The high corrosion resistance, low density, and useful biological activity with heat resistance of titanium alloys have made them the most outstanding choice in various industrial applications. However, their poor tribological properties inhibit utilizing them in applications that need abrasive and adhesive wear resistance. Laser cladding is being applied to increase the capabilities of such alloys by allowing the deposition of different hard coating materials. This paper attempts to study the thermal, microstructure, and clad layer geometry evolution during coaxial laser cladding of Ti6Al4V titanium alloy with tungsten carbide + nickel-based alloy preblended powder. Owing to the difficulty in experimentally measuring the thermal and microstructure evolution due to lots of laser processing parameters, a new three-dimensional numerical model based on finite-difference analysis for studying the entire process has been proposed. The behavior of the different thermophysical properties of WC, NiCrBSiC, and Ti6Al4V materials, as well as the phase transition based on latent heat and fluid dynamics considering materials velocity, viscosity, and buoyancy force, during melting and resolidification processes, were considered to improve and ensure the accuracy of the numerical model. The proposed model could be applied to accurately estimate the temperature history and the deposited clad layer morphology and geometry. The cooling rate and thermal gradient were investigated to predict the solidification rate and microstructure by using different laser cladding parameters. It was confirmed that the laser power has a substantial impact on the peak temperature in the melt-pool, while the laser scanning speed has a significant effect on the heating and cooling rates. In conclusion, the process parameters have to be carefully chosen to certify a good quality clad layer with the preservation of the WC particles.