To study the influence mechanism of process parameters on the temperature field and the repair performance in Inconel718 nickel-base-superalloy laser additive repairing process, numerical research was carried out. A three-dimensional finite element model was established, and the finite element software ANSYS was used to simulate the temperature field. The influence of the laser power, the scanning speed on the laser additive repairing temperature distribution and the penetration depth and width of the repair zone were analyzed. The numerical result and the experimental measurement result was compared, and the result showed that as the laser power is in the range of 229~668W and the cladding speed is in the range of 6~16mm/s, the metallurgical bond was formed between the repair layer and the matrix material. The maximum temperature at the interface between the repair layer and the substrate is proportional to the laser power and inversely proportional to the scanning speed. The theoretically calculated penetration depth and penetration width of the repair zone are basically consistent with the experimental measurement results. The theoretical simulation can provide theoretical guidance for the parameter optimization in the laser additive repairing process.
Laser surface hardening is one of the effective methods to enhance the mechanical properties of localised surface area of engineering parts made of different types of steels and other metals like ultra-high strength steel etc. Laser surface hardening has many advantages over conventional hardening process like, self-quenching, very fast, control over energy input and localised hardening etc. In order to further improve the surface quality and mechanical properties of 30CrMnSiNi2A ultra-high strength steel parts fabricated by laser deposition manufacturing (LDM). The quenching modified layer was prepared on the surface of 30CrMnSiNi2A steel by laser quenching technology. This work presents the effect of different laser parameters on the surface morphology and mechanical properties of 30CrMnSiNi2A steel after laser hardening. The experimental data of OM morphology, microstructure, micro-hardness and wear property of hardened layer were analyzed by using the methods of range analysis. Effects of these parameters over the micro hardness of the surface are described. It has been found that, there is around 20% increase in hardness after laser hardening. It considerably debased the surface roughness and wear rate of LDM 30CrMnSi2A alloy parts, which has decreased by 53% and 57% than without laser surface hardening parts. Accordingly, industrial applications of laser deposition manufacturing 30CrMnSi2A alloy parts were supposed to be widened by this study.
Aiming at the problems of tool wear and poor consistency in the mechanical subtraction of Inconel718 nickel-based superalloy complex structural parts in the laser additive and subtractive manufacturing process. In this paper, the short pulse laser is used to perform precision subtractive processing of Inconel 718 superalloy continuous laser deposition manufacturing (LDM) parts. This paper focuses on the research of short pulse laser milling and scanning technology of Inconel718 LDM. Based on the Response Surface Method, the influence of process parameters such as scanning speed, hatch distance and scanning times on the shape accuracy of the inner channel, surface roughness, material removal rate and recast layer was explored. The optimal milling process parameters are obtained as follows: the laser power is 100 W, the scanning speed is 6000 mm / s, the scanning times are 800, and the hatch distance is 0.02 mm.
In situ carbides (TiC/Cr7C3) reinforced CoCrMoNbTiC0.2 high-entropy alloy coatings were prepared on the Ti-6Al- 4V titanium alloy substrate by laser melting deposition technology. Effect of the laser power on the surface morphology, phase consistent, microstructure and microhardness were investigated. The results show that the coatings were composed of a simple BCC solid solution and a small amount of TiC and Cr7C3 carbides. The in-situ MC (TiC/Cr7C3) carbides were evenly distributed in the BCC matrix. The laser power has a significant impact on the forming quality and mechanical properties of the coatings. As the optimal laser power of 1500 W were applied, the coating mostly free of defects exhibited a fine dendritic microstructure. With the increasing laser power, the microhardness of the coatings was first increased and then decreased gradually. The highest microhardness of the coating (1500 W) was up to 650 HV0.5, which was 2 times higher than that of the substrate. The excellent mechanical properties of the coatings were attributed to the synergetic effects of the second phase strengthening, solid solution strengthening and fine microstructure.
Carbon Fiber Reinforced 1Plastic (CFRTS) and TC4 titanium alloy have excellent properties such as high stiffness, fatigue resistance and corrosion resistance, which are widely used in aerospace and new energy vehicle manufacturing. Due to the great differences in physical and chemical properties between CFRTS and TC4 titanium alloy, the traditional bonding and riveting methods have the problems of aging and stress concentration. This study introduces the interface composite control process of “picosecond laser cleaning and plastic-covered”. Firstly, CFRTS was subjected to laser cleaning pretreatment to remove the surface epoxy resin. Secondly, laser was used to pretreat the surface microstructure of TC4 titanium alloy. A layer of 0.02 mm PA powder was spread on the surface of the microstructure and melted by laser to form a plastic-covered layer. Finally, the treated CFRTS and TC4 titanium alloys were welded by laser-assisted joining. Compared with the traditional cleaning technology, it was found that the carbon fiber was exposed obviously and the structure was complete on the CFRTS surface after picosecond laser cleaning, and the epoxy resin was removed completely. The porosity of the joint interface is reduced, and the weld morphology is better. The shear strength of CFRTS-TC4 titanium alloy joint is significantly enhanced, and the maximum shear strength is 6333 N.
The laser deposition manufacturing (LMD) is a free-form metal deposition process, which allows generating a prototype or small series of near net-shape structures. Despite numerous advantages, one of the most critical issues of the technique is that produced pieces have a deleterious surface finish which requires post machining steps. Mechanical machining method such as milling and grinding has been used to improve the surface quality of the laser additive manufacturing components. However, the mechanical machining method has some drawbacks such as tool wearing and narrow-area difficult to machining. In this paper, we demonstrate the capability of continuous wave (CW) in polishing rough surface of additive manufactured TiAl alloy. The surface morphology, microstructures, corrosion resistance, micro-hardness and wear resistance of samples were characterized using a laser confocal microscopy (OM), scanning electron microscope (SEM), electrochemical analyzer, Vickers hardness machine, and wear tester, respectively. Results revealed that the surface roughness more than 16.06 μm could be reduce to less than 1.76 μm through laser polishing process. It was also found that a hardened layer about 600μm was produced on the TiAl alloy surface after laser finishing. The microhardness of the sample was improved about 8% compared with the mechanical milling method.
Laser additive manufacturing (LAM) is a novel technology that uses high-energy laser beam to obtain high performance entities and coatings. However, in this process, it is difficult to control the microstructure of materials effectively by changing the laser parameters. Based on this situation, we proposed a method that using direct electrostatic field (DESF) to assist LAM process. In this paper, we investigated the changes in 316L microstructure after assisted by DESF, and discuss the effect of electrostatic field. Microstructures of the 316L stainless steel sample fabricated by this method were tested. The result showed the solidification direction and grain morphology was influenced by the direction and value of DESF obviously. While the ESF direction is opposite to the laser scanning direction, the grains in the longitudinal-section perform orderly growth and the directions are biased to the laser scanning direction. While the DESF direction is the same as the scanning direction, the original solidification direction is obviously changed and the direction tended to be opposite to the scanning direction.
With the lightening tendency in the automobile and aircraft industry, the aluminium (Al) alloy and the carbon fiber reinforced thermal polymer (CFRTP) has been widely used. The CFRTP component always needs to be joined with Al alloy to form a CFRTP/Al alloy composite structure. Due to the large differences in the physicochemical properties of CFRTP and Al alloy materials, it is difficult to join with each other. Laser stir welding technology was applied to join CFRTP and Al alloy dissimilar materials in this research. In order to improve the CFRTP/Al alloy joining strength, a surface pre-treating method (laser micro-engraving) was proposed in this paper. Three micro-scale structures were designed and prepared on 7075 Al alloy by surface laser micro-treatment, which are linear grooves, mesh grooves and circular grooves. The morphology and dimensions (width and depth) of the microstructure on the strength of CFRTP / Al alloy joints were studied. The interface morphology and the fracture morphology of the joint were observed by the laser confocal microscopy and the scanning electron microscopy (SEM). Furthermore, the joining mechanism and failure mechanism of the CFRTP/Al alloy joint were explored. The results indicated that the microscale structures play an important role in improving the mechanical properties of Al alloy and CFRTP joins under different laser micro-engraving.
AlCrFeMnNi high-entropy alloy was prepared by laser additive manufacturing with gas-atomized pre-alloy powders. The phase, microstructure and microhardness of HEA have been investigated. The HEAs without electric field controlled and under controlled were composed of single BCC phase. Under the controlling of electric field, the pores presented the phenomenon of reducing. Due to the reducing of pores, the HEA under electric field controlled became harder and exhibited high microhardness of about 529.9 HV0.2, which was 6.49% higher than the HEA without controlled.
Due to the high manufacturing cost of Nickel based alloy compressor blisks, aero engine repairing process research has important engineering significance and economic value. Inconel718 Ni-based superalloy has the advantages of irradiation, corrosion resistance and excellent mechanical and processing properties. In this paper, a production process for the laser additive and subtractive hybrid manufacturing technologies was presented to repair a microcrack of Inconel 718. The whole repairing process includes four steps. Firstly, a pulsed laser was used to clean and etch the crack through materials subtractive. Secondly, a high-power continuous wave laser was used to additive material in the crack by laser deposition. Thirdly, a pulsed laser was applied to remove the excess repair material. Finally, a fiber laser was used to polish surface. The results showed that defect-free repair samples can be obtained with proper processing parameters. Metallurgical bonding could be achieved between the melting Inconel718 powder and the substrate under the action of a high-energy laser beam. The columnar dendrite and inter-dendritic structure in the repair zone are epitaxially grown along the deposition direction. The microstructure in the repair zone was fine and uniform due to the high gradient, high-speed solidification characteristics of the laser rapid fusion. The micro-hardness of the repaired tissue reduced to about 87% of the matrix and there was no new phase produced in the repair zone.
In this paper, the laser cladding method was used to preparation the TiC reinforced Ni-Fe-Al coating on the Ni base superalloy. The Ti/Ni-Fe-Al powder was preset on the Ni base superalloy and the powder layer thickness is 0.5mm. A fiber laser was used the melting Ti/Ni-Fe-Al powder in an inert gas environment. The shape of the cladding layer was tested using laser scanning confocal microscope (LSCM) under different cladding parameters such as the laser power, the melting velocity and the defocused amount. The microstructure, the micro-hardness was tested by LSCM, SEM, Vickers hardness tester. The test result showed that the TiC particles was distributed uniformly in the cladding layer and hardness of the cladding layer was improved from 180HV to 320HV compared with the Ni-Fe-Al cladding layer without TiC powder reinforced, and a metallurgical bonding was produced between the cladding layer and the base metal. The TiC powder could make the Ni-Fe-Al cladding layer grain refining, and the more TiC powder added in the Ni-Fe-Al powder, the smaller grain size was in the cladding layer.
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