Laser Cladding Process Research Articles

Optimization of defects and high temperature corrosion resistance of laser cladding FeCrAl coatings: Influence of process parameters

To enhance the surface quality and high-temperature corrosion resistance of FeCrAl coatings further, a laser cladding technique was employed to deposit Fe-13Cr-7Al coatings on the surface of 12Cr1MoV heat-resistant steel. The study investigated the influence of laser power, scanning speed, and powder feed rate on the quality and high-temperature corrosion resistance of the Fe-13Cr-7Al coatings. Utilizing 25 orthogonal experiments, coatings were prepared and evaluated through high-temperature corrosion tests to explore the corrosion resistance and mechanisms microstructural analysis of the coatings, including their elemental distribution and corrosion mechanisms, was conducted using optical microscopy (OM), X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). The optimal parameter combinations for laser cladding coatings were discussed. The results indicated that the coating quality was optimal within specific ranges of parameters (laser power 1875–2250 W, scanning speed 33–44 mm/s, powder feed rate 12–18 g/min); deviations outside these ranges led to issues such as incomplete coverage or coating detachment from the substrate. The structure of the laser cladded Fe-13Cr-7Al coatings consisted of columnar grains and α-Fe phase. In high-temperature corrosion testing, the coatings exhibited superior corrosion resistance compared to the substrate, with nearly twice the corrosion resistance variation observed under different process parameters. This study provides a scientific basis for optimizing laser cladding process parameters of Fe-13Cr-7Al coatings, demonstrating that precise control of process parameters significantly enhances the high-temperature corrosion resistance of coatings, thereby opening new possibilities for improving material performance in high-temperature applications.

Influence of overlapping process on the distribution of Cr element in laser cladding 316L powder on 45# steel substrate

To investigate the influence of the overlapping process on the distribution of Cr during the laser cladding process, a novel three-dimensional melting and solidification model based on the volume-average method coupled with Eulerian-Eulerian multiphase was established to simulate the process of laser cladding on a 45# steel substrate with different overlapping processes of 316 L powders. The reliability of the model was verified by comparing the simulation results with the melt pool morphology and melt flow rate measured by a high-speed camera. The height and depth of melt pool were verified through the cross-sectional metallographic diagram. The deviations of the melt pool height and depth for single-path cladding were 2.49 % and 6.35 %, respectively, while the deviations for overlapping process were 8.26 % and 6.88 %, respectively. The deviations of melt flow rate were 12.8 % for single-path cladding and 10.0 % for overlapping, respectively. The distribution of chromium (Cr) was verified based on the results of energy-dispersive spectroscopy (EDS), which demonstrated the accuracy of the model. The results demonstrate that reducing the overlapping rate during the overlapping process will increase the dilution rate of the second path of the molten cladding layer which in turn will decrease the concentration of Cr in the lapped area. Reverse overlapping, on the other hand, increases the temperature of the molten pool and the flow rate of the melt, resulting in a more homogeneous mixing of the elements within the second path of the cladding layer. This reduces the difference between the elemental concentration in the lapped area and the elemental concentration of the first and second paths of the cladding layer.

Effect of microstructure of overlapping regions on the wear/corrosion resistance performance of laser cladded Fe-based amorphous composite coatings

The issue of crystallization during the laser cladding process poses a significant challenge to the application of amorphous coatings. In order to explore the practical application of Fe41.5Co12.2Cr7.4Mo37.3C0.3B0.5Y0.4Al0.4 (at.%) amorphous composite coatings, this study fabricated coatings with different scanning speeds. The aim was to delve into their crystallization processes and assess the consequential effects on the coatings’ properties. The study revealed that crystallization predominantly occurs in the coatings’ overlapping region, which can be divided into two zones: the overlapping transition zone (OTZ) and the overlapping heat affected zone (OHAZ). The crystallization extent within the OHAZ is higher than in the OTZ, attributable to the disparate cooling rates characteristic of each region. With increasing scanning speed, the OHAZ gradually increases and the OTZ decreases. The coating prepared at 2000 mm/min has excellent corrosion resistance (polarization resistance 10,814.2 Ω·cm2) and wear resistance (wear rate (8.88±0.378)×10–6 mm3/N·m).

Enhancing corrosion and wear resistance of a 7075 aluminum alloy via depositing TC4 coating

Aluminum alloys have been widely used in engineering due to their high strength and low density. However, their poor corrosion and wear resistance have largely limited their application in marine equipment. This study successfully improved the corrosion and wear resistance of a typical 7075 Al alloy by depositing a high-performance TC4 titanium alloy coating using in-house annular laser cladding equipment. Microstructural investigations revealed that the defect-free TC4 coating is metallurgically bonded to the 7075 Al alloy substrate along with excellent bond strength. Electrochemical test results showed that compared to the hot-forged 7075 Al alloy and hot-forged double-phase TC4 bulk alloy, the TC4 coating exhibits superior corrosion resistance due to its net-basket α-single-phase microstructure. Further, wear testing results showed that the coefficient of friction and wear volume of the TC4 coating are far lower than that of 7075 Al alloy. The enhanced wear resistance is closely related to the high hardness of the TC4 coating and its excellent fatigue-wear resistance. Therefore, this work can serve as a reference to improve Aluminum alloys' corrosion and wear resistance by depositing Titanium alloy coatings using the annular laser cladding process, which shall widen the potential applications of Aluminum alloys in marine equipment.

Influence of high-reactivity energetic materials on microstructure and performance on iron-based cladding layer under low laser power

Abstract Under low laser power conditions, the cladding layer is constrained by inadequate energy density, resulting in incomplete melting of certain powder particles and the occurrence of defects such as cracks and pores within the layer. This paper utilizes a QT500 substrate and synergistically integrates high-reactivity energetic materials (H-REMs) with metal powder. By external laser energy ignition, the localized combustion of the H-REMs (Al + Fe2O3) is induced, thereby providing additional heat input during the laser cladding process. Through in-depth analysis of extensive experimental data, the influence of H-REMson microstructure and performance of alloy cladding layerhas beenrevealed. The research results demonstrate that the inclusion of H-REMs leads to a 450 K increase in the maximum temperature of the molten pool. By incorporating high-reactivity energetic materials, the energy density utilization of the composite material increased from 0.2663 to 0.7375. The combustion wave generated by H-REMs induces mixing in the molten pool, resulting in cladding layer grain refinement and an average hardness increase of 80 HV1. The friction coefficient decreases from 0.71024 (prior to the addition of H-REMs) to 0.35809, representing a reduction of approximately 49 %.

Comparative study on tensile and high cycle fatigue behaviour of 316L(N) SS hardfaced with Ni-Cr-B-Si alloy by GTA and laser cladding processes

In sodium-cooled fast reactors (SFR), 316L(N) SS grid plate is hardfaced with Ni-Cr-B-Si alloy to achieve higher wear resistance. Tensile and fatigue forces are acting at the interface between substrate and deposit due to different thermal expansion coefficients of those two materials, which can cause cracking of deposit and fracture during operation. Thus, it is very important to consider appropriate hardfacing method which can provide higher tensile and fatigue strength to avoid cracking/debonding at the interface. To find a solution to this problem, two hardfacing techniques, namely Gas Tungsten Arc (GTA) and Laser cladding (LC), are taken into consideration. Hardfaced specimens are prepared using each process on which tensile and high cycle fatigue tests are conducted. From the experimental testing, stress-strain and S-N curves are generated to predict the tensile and fatigue behaviour of specimens. Fractographic studies are conducted at fractured surfaces to understand the fatigue crack nucleation and propagation characteristics. The experimental results for both processes are compared. Tensile and fatigue strength of LC specimens are ∼11 % and ∼17 % less than those of GTA specimens due to its higher brittleness. Thus, GTA process is recommended as the efficient hardfacing process for grid plate of SFR.

Microstructures, high-temperature tribological and electrochemical mechanisms of FeCoNiCrAl high-entropy alloy coating prepared by laser cladding on a copper alloy: Combined TEM and DFT calculation

Two layers of FeCoNiCrAl coatings were prepared on copper (Cu) alloys substrates in this paper in order to improve the wear and corrosion performance of Cu alloys and to reduce the dilution of Cu in the laser cladding (LC) process. The microstructures, phase composition, microhardness, and crystal structure of the resulting coatings were analyzed, and their high-temperature tribological and electrochemical properties were tested. The results show that the surface of the HEA coatings still consists of a single-phase body-centered cubic (BCC) with low Cu content, and no generation of a second phase was observed. Compared with the substrate, the FeCoNiCrAl HEA coatings have better wear resistance, with oxidative wear and slight adhesive wear as the wear mechanism at 250 ℃. In addition, the FeCoNiCrAl HEA coating showed better electrochemical corrosion performance in 3.5 wt% NaCl solution. The corrosion mechanism is that the dense oxide layers inhibit the erosion of Cl- and high reaction barriers slow down electrochemical reactions.

Analysis and optimization of laser cladding Ti-B4C composite coatings based on the interaction and GABP-NSGAII algorithm

Laser cladding process parameters are important to the quality of cladding layer, but the interaction between parameters is not clear. In this work, the effects of parameters, especially interaction, on laser cladding of Ti-B4C coating were studied by orthogonal experiments. And the optimal process parameters were obtained by GABP-NSGAII multi-objective optimization algorithm. The results show that the interaction (B4C content and laser power) had the greatest effect on the coating aspect ratio, cladding angle, and dilution rate. The microhardness of the coatings prepared with the optimum parameters of 15 wt%, 2200 W, and 800 mm/min is 434 HV0.5, which consists of columnar, dendritic, and equiaxial structures from the interface to the surface, respectively. The interaction affects the molten pool flow and the distribution of unfused B4C particles, and influences the concentration and distribution of reinforcing phases in the coating, as well as the heat input and phase transitions in the heat affected zone. This paper provides a reference for the preparation of high-performance and high-quality titanium matrix composite coatings by laser cladding.

Forming mechanism of single-channel multilayer laser cladding Fe60 process under different laser heat source operating mode

Continuous wave (CW) and pulsed wave are the two principal modes of operation used to control the laser heat source. Different laser heat source operating modes have an essential impact on the rapid cooling and heating temperature change rate during the cladding process, which directly determines the cladding layer quality. The laser cladding process is meaningful to quantitatively reveal the mechanism of single-channel multilayer cladding and forming under different laser heat source operating modes. In this article, a multi-field coupled 3D numerical model of the single-channel multilayer cladding process under different laser operating modes was proposed, and the thermal physical parameters of the cladding material were computed on the basis of Calculation of Phase Diagrams method. The mechanism of the impact of distinct operating modes on the multi-field coupled ephemeral evolution process of laser cladding was investigated by using the solid/liquid interface tracking technique, which comprehensively considers the light powder interaction between the powder waist beam and the laser beam under different operating modes. The temperature, flow, and stress fields were computationally solved for a single-channel multilayer cladding process. On the foundation of this study, the impact mechanism of pulse duty cycle and pulse frequency on the cladding behavior of single-channel and multilayers during pulsed laser cladding were dissected. The macroscopic morphology and microstructure of the cladding layer were observed by KEYENCE VH-Z100R ultra-deep field electron microscope, and the feasibility of the model was confirmed. This study provides a significant theoretical rationale for enhancing the cladding quality under different laser operating modes.

Prediction of Geometric Characteristics of Laser Cladding Layer Based on Least Squares Support Vector Regression and Crested Porcupine Optimization.

The morphology size of laser cladding is a crucial parameter that significantly impacts the quality and performance of the cladding layer. This study proposes a predictive model for the cladding morphology size based on the Least Squares Support Vector Regression (LSSVR) and the Crowned Porcupine Optimization (CPO) algorithm. Specifically, the proposed model takes three key parameters as inputs: laser power, scanning speed, and powder feeding rate, with the width and height of the cladding layer as outputs. To further enhance the predictive accuracy of the LSSVR model, a CPO-based optimization strategy is applied to adjust the penalty factor and kernel parameters. Consequently, the CPO-LSSVR model is established and evaluated against the LSSVR model and the Genetic Algorithm-optimized Backpropagation Neural Network (GA-BP) model in terms of relative error metrics. The experimental results demonstrate that the CPO-LSSVR model can achieve a significantly improved relative error of no more than 2.5%, indicating a substantial enhancement in predictive accuracy compared to other methods and showcasing its superior predictive performance. The high accuracy of the CPO-LSSVR model can effectively guide the selection of laser cladding process parameters and thereby enhance the quality and efficiency of the cladding process.

Study on the reduction of residual stress in laser cladding layers through groove texture

In order to develop a method for the production of crack-free cladding layers, we combined surface texturing technology with laser cladding, establishing a multi-field coupled numerical simulation model. A separate investigation was conducted into the temperature, stress, and fluid fields in laser cladding processes with and without texturing, seeking optimal cladding parameters, and conducted experiments. The results of the numerical simulations indicate that pre-set texturing effectively reduces the temperature gradient during the cladding process, thereby making the thermal cycle curve smoother. The residual stresses in the X, Y, and Z directions are reduced by 34.84%, 3.94%, and 50.22%, respectively. The introduction of texturing reduces the internal flow velocity of the melt pool, preventing the occurrence of a double vortex effect. Experimental results show that the residual stresses in the X, Y, and Z directions of the predefined textured cladding layer are reduced by approximately 41%, 8%, and 47%, respectively, compared to the non-textured cladding layer. This effectively improves the surface roughness and internal grain size of the cladding layer, with no significant defects at the metallurgical bonding positions, providing a reference for future improvements in cladding layer quality.

Quantitative assessment method of thermal cycle accumulation mechanism during the pulsed laser single-channel multilayer cladding process

Pulsed laser cladding provides a periodical thermal accumulation, enabling a greater temperature gradient and cooling rate inside the substrate, which can efficiently ameliorate the microstructure of the cladding layer. It is crucial to quantitatively investigate the mechanism of the interaction for the cladding process parameters on the transient evolution of the multi-field coupling to improve the cladding quality. In this paper, a 3-D model during the single-channel multilayer pulsed laser cladding process was constructed which is grounded on the temperature-variable physical properties parameters of the material. The integrated consideration in the masking impact of the molten powder waist beam on the pulsed laser beam, the molten pool liquid metal surface tension, the influence of buoyancy on the flow, and the transient evolution of the molten pool edge morphology. The temperature, flow, and stress fields of the single-channel multilayer cladding process were computed and resolved. The mechanism in multi-field coupling impact of laser pulse frequency, laser power, and pulse duty cycle on the single-channel multilayer cladding process was emphasized. The response surface equations between each influencing factor and the cladding temperature, temperature change gradient, and thermal stress were determined according to the response surface method, and the sensitivity of each parameter was attained from the Monte Carlo method. Using SEM to observe the profile and microstructure of the cladding layer, the material hardness distribution was measured experimentally, and the effectiveness of the model was confirmed. This research supplies an essential rationale for upgrading the quality of pulsed laser cladding layers.

Laser cladding Ni60 @ WC/ Cu encapsulated rough MoS2 self-lubricating wear resistant composite coating and ultrasound-assisted optimization

This research aims to broaden the scope of self-lubricating wear-resistant coatings for applications in diverse industries such as automotive, metallurgy, power, and aerospace. Employing laser cladding technology, we successfully fabricated high-performance self-lubricating ceramic composite coatings. A comprehensive investigation was conducted to understand the inhibitory effect of Cu on the thermal decomposition of MoS2, and the study systematically explored the relationship between powder composition, coating structure, and organizational properties. The mechanisms behind friction reduction and wear resistance were unveiled, shedding light on the formation of the MoS2 self-lubricating protective film. Research findings reveal that during the laser cladding process, Cu and Ni undergo solid solution, resulting in the formation of the Cu–Ni alloy phase and crystal refinement. The MoS2 aggregation area exhibits a fine dendritic structure, while the dispersion area showcases coarse dendritic and cellular crystals. The addition of Cu and MoS2 influences the content of the MxCy phase and the thermal decomposition of MoS2. The incorporation of Cu increases the average coating hardness, whereas MoS2 addition decreases it; nevertheless, the Cu/MoS2 coating hardness is enhanced by at least 6.4 %. Cu significantly improves the coating's wear resistance, with a relatively smaller impact on friction reduction. MoS2 functions as a friction-reducing phase during wear, effectively preventing the peeling of hard phases and reducing the friction coefficient. Cu is uniformly distributed in the coating, experiencing solid solution strengthening, reducing adhesive region areas, and minimizing wear debris generation. MoS2, although unevenly distributed, forms intermittent lubricating films on the surface. The lubricating film of the Cu/MoS2 coating remains stable, preventing mutual contact of the friction surface and concurrently reducing the friction coefficient and wear amount. While the study successfully prepared a self-lubricating ceramic coating with excellent wear resistance, some surface quality defects persist. Further optimization of the preparation method was achieved through ultrasound-assisted technology.

Effects of Process Parameters on Microstructure and Wear Resistance of Laser Cladding A-100 Ultra-High-Strength Steel Coatings

To improve the hardness and wear resistance of mild steel, A-100 ultra-high-strength steel cladding coatings were prepared on the surface of mild steel by laser cladding. In this study, the effects of laser cladding process parameters on the forming quality, phase composition, microstructure, microhardness and wear resistance of the A-100 ultra-high-strength steel cladding coatings were researched. The results show that the main phase of the coating is martensite and a small amount of austenite. The microstructures of the upper part of the cladding coatings are mainly equiaxed grains, while those of the lower part are mainly columnar grains. With an increase in laser specific energy, the microstructures of the cladding coatings become coarse. When the laser specific energy is 70.8 J/mm2, the microhardness of the cladding coating is the highest, and the maximum average microhardness of the cladding coatings is 548.3 HV. When the laser specific energy is low, the wear of the cladding coatings is mainly pitting, while when the laser specific energy is high, the wear type of the cladding coatings is mainly adhesive wear. Moreover, the microhardness and wear resistance of the cladding coatings are reduced if the laser specific energy is too high.

Effect of laser power on morphology, microstructure and mechanical properties of CBN abrasive block prepared by two-step laser cladding

The preparation of cubic boron nitride (CBN) grinding tools using laser cladding has the advantages of strong bonding, short time consumption and customizable abrasive arrangement. In this paper, a two-step laser cladding method was used to prepare CBN abrasive blocks with the aim of reducing laser damage to CBN grits during the laser cladding process. The cross-sectional morphology of CBN abrasive blocks under different laser power conditions was characterized, and the relationship among laser power, preparation method, and forming quality of Cu–Sn–Ti/CBN cladding layer was investigated. Then, the microstructure at the Cu–Sn–Ti/CBN interface under different laser power conditions was characterized, and the main phase compositions at the Cu–Sn–Ti/CBN interface were analyzed. Finally, the grinding tests were carried out on CBN abrasive blocks. The results show that as the laser power increases from 250 W to 400 W, the fracture ratio of CBN grits increases dramatically from 4.3 % to 17.3 %. TiN, TiB2, and TiB compounds are all detected at the Cu–Sn–Ti/CBN interface under different laser power conditions. The mass loss of the TC4 wheel caused by the CBN abrasive block initially increases and then decreases as the laser power increases from 250 W to 400 W. The CBN abrasive block has the optimum material removal performance at the laser power of 300 W using two-step laser cladding. The results provide a theoretical basis for the preparation of high-performance CBN grinding tools using laser cladding.

Laser-directed energy deposition of bioactive glass on Ti-6Al-7Nb titanium alloy substrate with highly refined grain structure

The bioactive glass S520 was applied to an ultrafine-grained Ti-6Al-7Nb titanium alloy by a laser-directed energy deposition (LDED) process, in order to create a biocompatible material without potentially toxic vanadium for use in load bearing biomedical implants. The laser cladding process influenced the substrate's structure by melting the metallic material at the surface and infusing it with bioactive glass. Subsequently, the melted titanium alloy crystallised, resulting in the formation of relatively large grains. Deeper into the material, laser-induced heat triggered martensitic transformation, leading to the formation of α′ acicular martensite. In the lower regions of the HAZ, a distinctive band with refined grains was identified. Detection of certain amounts of Al directly in the bioactive glass raises concerns about potential toxicity as the glass dissolves in the human body. The nearly complete reduction in P concentration after 14 days highlights the high bioactivity of the material produced.

A Review on Effect of Cooling Rate on Metallurgical, Mechanical, Geometrical Characteristics and Defects of Laser Cladding Process

A Review on Effect of Cooling Rate on Metallurgical, Mechanical, Geometrical Characteristics and Defects of Laser Cladding Process

In-situ determination of micro-hardness in laser cladding of stellite using optical emission spectroscopy

Offline measurements in Laser Cladding (LC) processes, such as micro-hardness measurement, are destructive and time-consuming tests. Therefore, in-situ monitoring of clads parameters is of significant importance. In this study, we investigate the plasma plume emission produced during the LC process of Stellite 6 powder on a low-carbon steel substrate and its correlation with the micro-hardness of the clads over a wide range of LC parameters. It is demonstrated that a strong correlation between the spectral features in the UV region of 280–320 nm and micro-hardness exists, so that, the micro-hardness of samples can be determined by the total intensity of light in this range, within an average tolerance of 10 %. An exponential relation between hardness and UV radiation is empirically obtained that works very well for a wide range of dilutions, from 20 % to 70 %. It means that the UV spectra even determine the micro-hardness of samples with dilutions above 60 %, where the process shifts towards laser powder welding. This radiation is suggested to originate from the collisions of electrons with nano-sized clusters, which are produced during the laser interaction with the melt pool. The produced nanoparticles are the source of UV radiation and scatters the driving laser light, at the same time, processes that qualitatively explain the exponential relationship between the hardness and the UV light intensity.

Tribological behavior of low carbon steel, grade AISI1018 overlayed with nickel based MMC plus WC

Friction Coefficient (FC), Rate of specific wear (RSW) of low carbon steel of grade AISI 1018 overlayed with nickel-based MMC plus WC using laser cladding were investigated in this tribological study. Specimens were pressed up on to a rotating steel disc (EN31), experiments were conducted on low carbon steel and low carbon steel overlayed with nickel-based MMC plus WC on a pin-on-disc machine. MMC based on nickel were layered over low carbon steel using the laser cladding process. A set of samples were used in the experiments, which lasted 20 minutes and involved loading conditions of 10N, 20N, 30N, 40N, and 50N with sliding distances ranging from 1000 m to 3000 m. The findings demonstrate how different loads and sliding distances affect the SWR and CoF. Generally, speaking, CoF rises during the rubbing phase and then stays steady for the duration of the test. The obtained results indicate that, for cladded material, the FC and RSW increase with increasing applied load and sliding distance.RSW and FC of Low Carbon Steel overlayed with Nickel based MMC plus WC, which was created using the Laser Cladding Process, decreased. When compared to low carbon steel, the RSW of low carbon steel overlayed with nickel-based MMC plus WC that was created using laser cladding decreased to 31.26%. CoF of low carbon steel covered with MMC plus WC based on nickel, created by laser cladding, is found to be 12.13% lower. To investigate the worn surfaces of the base metal, a Scanning Electron Microscope (SEM) was used, which is low carbon steel and low carbon steel layered with nickel-based MMC plus WC using laser cladding. Two types of samples had worn surfaces with shallow and fine grooves at low loads, and large quantities of cracks at high loads, which raised weight loss.

Quality enhancement of crack-free laser-cladded NiCrSiBC-WC coating by in-situ temperature field assistance (ITFA) and post-laser remelting (PLR)

WC/Ni-based composite coatings have received much attention in recent years. However, the application of laser cladded WC/Ni-based coatings encounters many issues, such as WC particle distribution inhomogeneity and coating cracking. In this study, the integrated method of in-situ temperature field assistance and post-laser remelting (ITFA+PLR) is proposed for NiCrSiBC-WC coating preparation and compared with mere ITFA and PLR. The results show that the three methods eliminate cracks and enhance overall mechanical qualities, outcompeting the single laser cladding process even with higher WC concentration. ITFA helps the interfacial reaction of the WC particles, while PLR distributes large-sized WC particles and produces and disperses refined carbides. With this, ITFA+PLR combines their benefits and achieves a uniform distribution of fine carbides and original WC. When the phases are analyzed, the relationship between microstructure (i.e., large-sized WC and fine carbides) and coating hardness is quantified and established, yielding a generalized microhardness index. With this unitless microhardness index, it is discovered that the increased density of fine carbides dominates the hardness increase. In summary, ITFA+PLR promotes fine carbide formation, improves its distribution, and obtains the highest hardness for NiCrSiBC-WC coating. With the generalized carbide phase-determined microhardness index, this paper guides the design of crack-free WC/Ni-based coatings and enlightens the improvement of NiCrSiBC-WC coating's mechanical properties.