Extreme high-speed laser cladding (EHLC) has shown potential in producing refractory high entropy alloy (RHEA) coatings with excellent forming quality. However, there is a lack of theoretical guidance for the EHLC process, and the traditional heat source model is unsuitable. In this study, the laser-molten metal composite heat source model was improved based on the characteristics of EHLC, and a temperature field model suitable for EHLC tubular matrix surface was established and verified by infrared thermal imaging. The solidification characteristics and microstructure of TaNbZrTi RHEA coating prepared by laser cladding (LC), high-speed laser cladding (HLC), and EHLC were compared through temperature field simulation and experimental characterization. The results indicate that the cooling rate of molten pool increases significantly with the increase of scanning speed. EHLC coating has higher cladding efficiency, lower heat accumulation and dilution rate, and denser grain structure compared to LC and HLC coatings. TaNbZrTi coating exhibits a BCC1 + BCC2 phase structure, and the hardness of LC, HLC, and EHLC coating is 577.5, 487.8, and 545.2 HV0.3, respectively. This study provides a simulation model and process guidance for the preparation of TaNbZrTi RHEA coatings.
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