High-power laser beam shaping by inseparable two-dimensional binary-phase gratings for surface modification of stamping dies

For surface modification of stamping dies, an inseparable two-dimensional binary-phase gratings is introduced to implement the wavefront transformation of high-power laser beams. The design and fabrication of the gratings are described in detail. Two-dimensional even sampling encoding scheme is adopted to overcome the limitations of conventional Dammann grating in the design of two-dimensional output patterns. High diffractive efficiency (>70%) can be achieved through the transformation of the Gaussian laser beam into several kinds of two-dimensional arrays in focal plan. The application of the binary-phase gratings in the laser surface modification of ductile iron is investigated, and the results show that the hardness and the wear resistance of the sample surface were improved significantly by using the binary-phase gratings. (C) 2008 Elsevier Ltd. All rights reserved.

Nanoindentation of thin-film-substrate system: Determination of film hardness and Young's modulus

In the present paper, the hardness and Young's modulus of film-substrate systems are determined by means of nanoindentation experiments and modified models. Aluminum film and two kinds of substrates; i.e. glass and silicon, are studied. Nanoindentation XP II and continuous stiffness mode are used during the experiments. In order to avoid the influence of the Oliver and Pharr method used in the experiments, the experiment data are analyzed with the constant Young's modulus assumption and the equal hardness assumption. The volume fraction model (CZ model) proposed by Fabes et al. (1992) is used and modified to analyze the measured hardness. The method proposed by Doerner and Nix (DN formula) (1986) is modified to analyze the measured Young's modulus. Two kinds of modified empirical formula are used to predict the present experiment results and those in the literature, which include the results of two kinds of systems, i.e., a soft film on a hard substrate and a hard film on a soft substrate. In the modified CZ model, the indentation influence angle, phi, is considered as a relevant physical parameter, which embodies the effects of the indenter tip radius, pile-up or sink-in phenomena and deformation of film and substrate.

非转移弧层流等离子体射流熔凝铸铁表面耐磨性的研究

对在大气压条件下用非转移弧层流等离子体射流熔凝强化处理的W-Mo-Cu铸铁表面,采用光学显微镜、显微硬度计、磨损试验机、扫描电镜等,观察和测试了熔凝试样的表面层组织、硬度、耐磨性和磨损形貌.结果表明,熔凝后铸铁表面为初晶渗碳体和莱氏体组成的过共晶组织,硬度和耐磨性有了明显的提高.

Formation and Structure of Composite Coating of HAD and Micro-Plasma Oxidation on A3 Steel

Composite coatings were obtained on A3 steel by hot dipping aluminum(HAD) at 720 degreesC for 6 min and micro-plasma oxidation (MPO) in alkali electrolyte. The surface morphology, element distribution and interface structure of composite coatings were studied by means of XRD, SEM and EDS. The results show that the composite coatings obtained through HAD/MPO on A3 steel consist of four layers. From the surface to the substrate, the layer is loose Al2O3 ceramic, compact Al2O3 ceramic, At and FeAl intermetallic compound layer in turn. The adhesions among all the layers are strengthened because the ceramic layer formed at the At surface originally, FeAl intermetallic compound layer and substrate are combined in metallurgical form through mutual diffusion during HAD process. Initial experiment results disclose that the anti-corrosion performance and wear resistance of composite coating are obviously improved through HAD/MPO treatment.

A Study of the Tribological Behavior of Carbon-Nanotube-Reinforced Ultrahigh Molecular Weight Polyethylene Composites

The tribological properties of the high-strength and high-modulus ultrahigh molecular weight polyethylene (UHMWPE) film and the UHMWPE composites reinforced by multiwalled carbon nanotubes (MWCNT/UHMWPE) were investigated using a nanoindenter and atomic force microscope (AFM). The MWCNT/UHMWPE composites films exhibited not only high wear resistance but also a low friction coefficient compared to the pure UHMWPE films. We attribute the high wear resistance to the formation of the new microstructure in the composites due to the addition of MWCNTs.

脉冲激光离散重熔热物理及组织性能研究

利用OM及FEM研究了铁基合金Nd:YAG脉冲激光熔凝区的几何形态及其变化规律、以及熔凝的热物理过程；利用OM、SEM、TEM、X-射线衍射仪及磨损实验机，研究了两种铁基热模具材料脉冲激光熔凝组织及其时效组织结构，以及熔凝区规则离散分布规律对材料抗磨损性能的影响。在10~5～10~7W/cm~2的脉冲激光平均功率密度范围内，可得到热传导型和深熔型两类强化区，当临界平均功率密度大于5 * 10~5W/cm~2，同时临界激光作用时间大于2ms时，热传导型强休区向深熔型强休区转变。熔化过程中，在熔池中形成上部以对流传热为主，底部以导热为主的传热模式，流场、温度场和压力场均随脉冲激光作用时间变化，最大流速、压力和温度梯度分别可达100m/s、数个大气压和10~(8-9) ℃C/m量级。凝固过程中，固液界面上的最大温度梯度、凝固速率和冷却速度时间和空间位置变化，分别可达10~(8-9) ℃/m量级、10~(-1)m/s量级和10~(7-8) ℃/s量级，其中冷却速度得到实验验证。亚共晶合金铸铁脉冲激光熔凝组织为δ-铁素体与M_3C的层片状共晶组织，还含有部分γ-奥氏体和少量的高碳孪晶马氏体组织，δ-铁素体和γ-奥氏体中均存在高密度位错亚结构。5CrMnMo钢脉冲激光熔凝组织由板条马氏体及少量的孪晶马氏体构成，马氏体中也存在高密度位错亚结构。上述两种组织经高温时效后，仍保持较细的晶粒，并有大量细小均匀弥散分布的碳化物析出，其中铸铁熔凝组织析出M_(23)C_6碳化物，M_(23)C_6可在M_3C/γ-奥氏体相界面或M_3C内部原位形核，亦可在δ-铁素体中弥散析出。两种材料的熔凝组织及其时效组织的显微硬度均明显高于相应的原始组织，也高于激光连续扫描熔凝的结果。脉冲激光规则离散熔凝加工在材料表面形成软硬相间的“原位”功能层，能显著降低裂纹形成的敏感性，提高材料表层的抗磨粒磨损性能，时效后仍具有较好的抗磨损性能。以熔凝强化区直径作为中心间距进行规则离散熔凝处理可使材料表面获得最佳抗磨损性能。

铁基激光熔覆合金设计及微观组织与性能研究

本文设计并制备了具有优良的强韧性能和高温性能的激光熔覆涂层。利用 SEM、TEMEY X－射线衍射仪等研究了涂层的化学成分、宏微观结构及其转变机制，同时研究了涂层强韧性及耐高温磨损性能及其影响机制。对激光溶覆涂层进行了合金化、微观组织、强韧化机制、加工工艺性能设计。合金系为 Fe-Cr-C-W-Ni，成分配比（质量分数），Fe:52-60%, Cr:24-30%, C:5-6%, W:4.5-7.5%, Ni:5-6%。强化机制为两相强化、亚结构强化及固溶强化，其中强化相为合金碳化物，基体相为合金元素过饱和度极高的韧性奥氏体。亚共晶及过共晶组织的领先凝固相分别为奥氏体及 M_7C_3 合金碳化物，两相共晶组织均为韧性相奥氏体和强化相 M_7C_3 合金碳化物。加工工艺控制领先凝固相的结构、组织演化及力学性能。熔覆组织在高温时效过程中形成大量新的碳化物。在过饱和奥氏体内部，可弥散析出细小的 Mc、M_2C 及 M_(23)C_6碳化物；在奥氏体与 M_7C_3 相界面，亚稳相M_7C_3发生原位转变，形成 M_(23)C_6 及 M_6C碳化物。激光熔覆合金具有较高的综合力学性能，熔覆涂层有高的显微硬度、优良的抗回火稳定性、显著的二次硬化特征、优异的抗磨粒磨损和冲击磨损性能。Fe-Cr-C-W-Ni 激光熔覆合金具有较低的裂纹形成倾向和良好的表面成形性能，这与奥氏体较高的高温韧塑性及合金的低熔点共晶特征密切相关；实验及理论分析表明，通过调整合金成分、激光工艺参数和后续热处理工艺，可获得具有不同强韧性能的熔覆涂层。

激光热处理对化学沉积Ni-P合金薄膜性能的影响

用扫描电镜(SEM)观察了化学沉积Ni-P合金薄膜/单晶硅基体的结构与颗粒度,利用X射线衍射(XRD)技术测试了其化学沉积后的残余应力,测量了激光热处理后残余应力的变化规律,分析了残余应力对磨损性能及界面结合强度的影响。实验结果表明,化学沉积Ni-P合金薄膜/硅基体的残余应力均表现为拉应力,经过激光热处理后残余应力发生了变化,由高值的拉应力变为低值的拉应力或压应力；薄膜残余应力对其磨损性能有明显的影响,其磨损量随着残余应力的减小而减小；薄膜与基体结合强度随着残余应力的增大而减小,合理地选择激光热处理参数可