Study on microstructure and mechanical properties of Ni60 + WC/Ni35/AISI1040 functional surface gradient structure of remanufacturing chute plate for the mining scraper by a low cost high power CO2 laser cladding technique

Abstract

CO2 laser cladding is a type of green remanufacturing technology, which is of many technical advantages in repairing and remanufacturing industry, especially for some large-scale key mining equipment or parts due to its characteristics of high quality, high efficiency and environmental protection (e.g. energy and material saving). In this paper, the chute plate of coal mining scraper is fixed and remanufactured by CO2 laser cladding technique. Ni60, WC, Ni35, IG55 and other composite powders are selected to design and build the gradient functional structure for chute plate in order to improve the reproduced lifetime. A lot of high power low cost CO2 laser cladding tests are carried out on the matrix material (AISI 1040 steel plate) of old attrite chute plate. The optical microscope, SEM, XRD, microhardness test and wear experiment are adopted to analyze the relationships among the laser cladding process, the overlaying composite material, gradient functional structure and mechanical properties of the remanufacturing scraper’s chute plate. The research results show that laser power and scanning speed are the dominant cladding process parameters, which have a significant influence on the geometric dimension (including width and height), dilution rate and hardness of the deposited layer. These composite powders (especially including the rare earth metals) are the key factor to form the gradient functional structure. The laser cladding Ni60 + WC/Ni35/AISI1040 composite gradient functional structure has a reasonable toughness and strength of the transition layer structure, and a high hardness and wear-resistant surface functional layer, so the fixed and remanufactured product has formed good ductile plasticity and wear resistance properties as a result of the gradient functional structure. The unique Ni60 + WC/Ni35/AISI1040 gradient functional structure makes sure that the chute plate of mining scraper has excellent comprehensive performance, which is satisfied with the service requirements of mechanical parts or equipment in the harsh working environment of the mining industry. This research work provides technological guidance for the fix and remanufacturing chute plate, and achieves the goal of low cost, high efficiency and long life reproduced chute plate of mining scraper.