表面熔覆工艺的成形特征及粉末有效利用率研究
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摘要
目的针对激光熔覆层的表面形貌难以达到加工工艺要求和粉末利用率较低的问题,对激光熔覆铁基合金粉末中的工艺参数与成形特征的关系以及粉末的有效利用率进行研究。方法设计了激光表面熔覆试验方案,分别采用不同的工艺参数在45号钢基板上进行铁基合金粉末单道激光熔覆试验。采用正交试验法对每道激光熔覆试验的工艺参数与成形特性之间的关系进行研究。结果随着激光功率的增加,熔宽、熔深、稀释率均呈上升趋势,浸润角和熔覆层的高宽比呈下降趋势,粉末的有效利用率由12.9%上升到42.6%;随着送粉速度的增加,熔高呈现上升趋势,熔深呈现下降趋势,粉末的有效利用率由27.9%下降到14.7%;随着激光扫描速度的增加,熔宽和熔高均呈下降趋势,粉末的有效利用率先增加后下降。结论送粉速度的增加造成粉末有效利用率的降低,增加了激光熔覆的作业成本。适当增加激光功率不仅可获得更加良好的激光熔覆层形貌,也使得粉末有效利用率增加。在激光功率为450 W,送粉速度为9.6 g/min和激光扫描速度为390 mm/min的条件下,不仅可以使粉末有效利用率处于较高的状态,也可以获得良好的熔覆层形貌。以上研究结果对激光熔覆的应用具有指导性作用。
The work aims to study the relationship between processing parameters and forming characteristics in laser cladding of Fe-based alloy powder and powder effective utilization rate for the problem that surface geometry of cladding layer is difficult to reach the processing requirements and the utilization rate of powder is lower. Test plan of laser surface cladding was designed and Fe-based alloy powder was used for single track laser cladding on the 45# steel substrate with different processing parameters. The relationship between processing parameters and forming characteristics of each laser cladding test was researched by orthogonal test. With the increase of laser power, clad width, melt pool depth and dilution rate increased, but infiltration angle and aspect ratio of cladding layer decreased. Meanwhile, powder effective utilization increased from 12.9% to42.6%. With the increase of powder feed rate, clad height increased. However, melt pool depth decreased, and powder effective utilization decreased from 27.9% to 14.7%. With the increase of laser scanning velocity, clad width and clad height deceased,and powder effective utilization increased first and then decreased. Therefore, effective utilization of powder decreases as powder feed rate increases, which increases the cost of laser cladding. However, the proper increase of laser power can not only obtain good cladding layer geometry, but also increase effective utilization of powder. Under the condition of 450 W, 9.6 g/min and390 mm/min, the powder effective utilization is high and good geometry of cladding layer is obtained. These experiment results provide some references for the application of laser cladding.
The work aims to study the relationship between processing parameters and forming characteristics in laser cladding of Fe-based alloy powder and powder effective utilization rate for the problem that surface geometry of cladding layer is difficult to reach the processing requirements and the utilization rate of powder is lower. Test plan of laser surface cladding was designed and Fe-based alloy powder was used for single track laser cladding on the 45# steel substrate with different processing parameters. The relationship between processing parameters and forming characteristics of each laser cladding test was researched by orthogonal test. With the increase of laser power, clad width, melt pool depth and dilution rate increased, but infiltration angle and aspect ratio of cladding layer decreased. Meanwhile, powder effective utilization increased from 12.9% to42.6%. With the increase of powder feed rate, clad height increased. However, melt pool depth decreased, and powder effective utilization decreased from 27.9% to 14.7%. With the increase of laser scanning velocity, clad width and clad height deceased,and powder effective utilization increased first and then decreased. Therefore, effective utilization of powder decreases as powder feed rate increases, which increases the cost of laser cladding. However, the proper increase of laser power can not only obtain good cladding layer geometry, but also increase effective utilization of powder. Under the condition of 450 W, 9.6 g/min and390 mm/min, the powder effective utilization is high and good geometry of cladding layer is obtained. These experiment results provide some references for the application of laser cladding.
引文
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[16]顾玉芬,苏艳文,朱明,等.激光-氩弧焊电弧复合热源表面熔覆工艺及成形特征[J].上海交通大学学报,2016,50(12):1902-1905.GU Yu-fen,SU Yan-wen,ZHU Ming,et al.Technology and forming characteristics of laser tungsten inert gas hybrid heat source surface cladding[J].Journal of Shanghai Jiao Tong University,2016,50(12):1902-1905.
[17]闫世兴,董世运,徐滨士,等.Fe314合金熔覆层残余应力激光冲击消除机理[J].中国激光,2013,40(10):102-107.YAN Shi-xing,DONG Shi-yun,XU Bin-shi,et al.Mechanics of removing residual stress of Fe314 cladding layers with laser shock processing[J].Chinese journal of laser,2013,40(10):102-107.
[2]尹泉,彭如恕,朱红梅.激光熔覆原位生成增强相强化铁基涂层性能研究[J].表面技术,2016,45(4):99-104.YIN Q,PENG R S,ZHU H M.Performance improvement of iron base coating by laser cladding in-situ generated reinforced phase[J].Surface technology,2016,45(4):99-104.
[3]臧辰峰,赵鹏飞,张小彬,等.碳钢表面激光熔覆镍基合金涂层及其高温磨损行为[J].东北大学学报(自然科学版),2009,30(10):1437-1440.ZANG Chen-feng,ZHAO Peng-fei,ZHANG Xiao-bin,et al.Laser cladding of Ni-based alloy on#20 steel surface and its high-temperature abrasive-wear behavior[J].Journal of Northeastern University(Natural science),2009,30(10):1437-1440.
[4]PARTES K.Analytical model of the catchment efficiency in high speed laser cladding[J].Surface and coatings technology,2009,204(3):366-371.
[5]OCELIK V,DE OLIVEIRA U,DE BOER M,et al.Thick Co-based coating on cast iron by side laser cladding:analysis of processing conditions and coating properties[J].Surface and coatings technology,2007,201(12):5875-5883.
[6]宋建丽,李永堂,邓琦林,等.激光熔覆成形技术的研究进展[J].机械工程学报,2010,46(14):29-39.SONG Jian-li,LI Yong-tang,DENG Qi-lin,et al.Research progress of laser cladding forming technology[J].Journal of mechanical engineering,2010,46(14):29-39.
[7]袁庆龙,冯旭东,曹晶晶,等.激光熔覆技术研究进展[J].材料导报,2010,24(3):112-116.YUAN Qing-long,FENG Xu-dong,CAO Jing-jing,et al.Research progress in laser cladding technology[J].Materials review,2010,24(3):112-116.
[8]HOFMAN J T,DE LANGE D F,PATHIRAJ B,et al.FEM modeling and experimental verification for dilution control in laser cladding[J].Journal of materials processing technology,2011,211(2):187-196.
[9]KIM J D,PENG Y.Melt pool shape and dilution of laser cladding with wire feeding[J].Journal of materials processing technology,2000,104(3):284-293.
[10]李爱农,魏成靓,刘娇姣,等.激光熔覆铁基Cr3C2/Mo S2覆层的组织和摩擦磨损性能[J].中国表面工程,2015,28(5):77-85.LI Ai-nong,WEI Cheng-liang,LIU Jiao-jiao,et al.Microstructure,friction and wear properties of laser cladding Fe-based Cr3C2/Mo S2 coatings[J].China surface engineering,2015,28(5):77-85.
[11]LALAS C,TSIRBAS K,SALONITIS K,et al.An analytical model of the laser clad geometry[J].The international journal of advanced manufacturing technology,2007,32(1):34-41.
[12]FATHI A,TOYSERKANI E,KHAJEPOUR A,et al.Prediction of melt pool depth and dilution in laser powder deposition[J].Journal of physics D:applied physics,2006,39(12):2613.
[13]NAKKI J,TUOMINEN J,VUORISTO P.Effect of minor elements on solidification cracking and dilution of alloy625 powders in laser cladding[J].Journal of laser applications,2017,29(1):012014.
[14]JENDRZEJEWSKI R,KREJA I,SLIWINSKI G.Temperature distribution in laser-clad multi-layers[J].Materials science and engineering:A,2004,379(1):313-320.
[15]张庆茂,刘喜明,孙宁,等.送粉式宽带激光熔覆--搭接基础理论的研究[J].金属热处理,2001(2):25-28.ZHANG Qing-mao,LIU Xi-ming,SUN Ning,et al.Fundamental investigation on overlapping coating formed by broad-beam powder feeding cladding[J].Heat treatment of metals,2001(2):25-28.
[16]顾玉芬,苏艳文,朱明,等.激光-氩弧焊电弧复合热源表面熔覆工艺及成形特征[J].上海交通大学学报,2016,50(12):1902-1905.GU Yu-fen,SU Yan-wen,ZHU Ming,et al.Technology and forming characteristics of laser tungsten inert gas hybrid heat source surface cladding[J].Journal of Shanghai Jiao Tong University,2016,50(12):1902-1905.
[17]闫世兴,董世运,徐滨士,等.Fe314合金熔覆层残余应力激光冲击消除机理[J].中国激光,2013,40(10):102-107.YAN Shi-xing,DONG Shi-yun,XU Bin-shi,et al.Mechanics of removing residual stress of Fe314 cladding layers with laser shock processing[J].Chinese journal of laser,2013,40(10):102-107.