Interfacial microstructure and mechanical behaviour in laser clad TiCp/Ni alloy coatings

Coatings of TiCp reinforced composite have been produced by laser cladding. Two kinds of coating with different TiCp origins were investigated, i.e. undissolved TiCp and in situ TiCp. For undissolved TiCp, epitaxial growth of TiC, precipitation of CrB, and a chemical reaction occur at phase interfaces, and nanoindentation loading curves show pop in marks caused by the plastic deformation associated with crack formation or debonding of TiCp from the matrix. As for in situ TiCp, no pop in mark appears. Meanwhile, in situ TiCp produces hardness and elastic modulus values that are higher than those produced by the coating that contains undissolved TiCp.

Microstructure and mechanical properties at TiCp/Ni-alloy interfaces in laser-synthesized coatings

Titanium carbide particle (TiCp) reinforced Ni alloy composite coatings were synthesized by laser cladding using a cw 3 kW CO2 laser. Two kinds of coatings were present in terms of TiCp origins, i.e. undissolved and in situ reacted TiCp, respectively. The former came from the TiCp pre-coated on the sample, whereas the latter from in situ reaction between titanium and graphite in the molten pool during laser irradiation. Conventional and high-resolution transmission electron microscope observations showed the epitaxial growth of TiC, the precipitation of CrB, and the chemical reaction between Ti and B elements around phase interfaces of undissolved TiCp. The hardness, H, and elastic modulus, E, were measured by nanoindentation of the matrix near the TiCp interface. For undissolved TiCp, the loading curve revealed pop-in phenomena caused by the plastic deformation of the crack formation or debounding of TiCp from the matrix. As for in situ generated TiCp, no pop-in mark appears. On the other hand, in situ reacted TiCp led to much higher hardness and modulus than that in the case of undissolved TiCp. The coating reinforced by in situ generated TiCp displayed the highest impact wear resistance at both low and high impact conditions, as compared with coatings with undissolved TiCp and without TiCp. The impact wear resistance of the coating reinforced by undissolved TiCp increases at a low impact work but decreases at a high impact work, as compared with the single Ni alloy coating. The degree of wear for the composite coating depends primarily on the debonding removal of TiCp.

Rapidly solidified nonequilibrium microstructure and phase transformation of laser-synthesized iron-based alloy coating

The rapidly solidified microstructural and compositional features, the precipitation and transformation of carbides during tempering, and the impact wear resistance of an iron-based alloy coating prepared by laser cladding are investigated. The clad coating alloy, a powder mixture of Fe, Cr, W, Ni, and C with a weight ratio of 10:5:1.1.1, is processed using a continuous wave CO, laser. Microstructural studies demonstrate that the coating possesses the hypoeutectic microstructure comprising the primary dendritic gamma-austenite and interdendritic eutectic consisting of gamma-austenite and M7C3 carbides. gamma-Austenite is a non-equilibrium phase with an extended solid solution of alloying elements. During high temperature tempering at 963 K for 1 h, the precipitation of M23C6, MC and M2C carbides in austenite and in situ carbide transformation of M7C3 to M23C6 and M7C3 to M6C respectively are observed. In addition, the microstructure of the laser-clad coating reveals an evident secondary hardening and a superior impact wear resistance.

Laser synthesizing NiAl intermetallic and TiC reinforced NiAl intermetallic matrix composite

The NiAl intermetallic layers and NiAl matrix composite layers with TiC particulate reinforcement were successfully synthesized by laser cladding with coaxial powder feeding of Ni/Al clad powder and Ni/Al + TiC powder mixture, respectively. With optimized processing parameters and powder mixture compositions, the synthesized layers were free of cracks and metallurgical bond with the substrate. The microstructure of the laser-synthesized layers was composed of 6-NiAl phase and a few gamma phases for NiAl intermetallic; unmelted TiC, dispersive fine precipitated TiC particles and refined beta-NiAl phase matrix for TiC reinforced NiAl intermetallic composite. The average microhardness was 355 HV0.1 and 538 HV0.1, respectively. Laser synthesizing and direct metal depositing offer promising approaches for producing NiAl intermetallic and TiC-reinforced NiAl metal matrix composite coatings and for fabricating NiAl intermetallic bulk structure. (C) 2004 Laser Institute of America.

Microstructure and high-temperature wear and oxidation resistance of laser clad gamma/W2C/TiC composite coatings on gamma-TiAl intermetallic alloy

There are very strong interests in improving the high-temperature wear resistance of the y-TiAl intermetallic alloy, especially when applied as tribological moving components. In this paper, microstructure, high-temperature dry sliding wear at 600 degrees C and isothermal oxidation at 1000 degrees C on ambient air of laser clad gamma/W2C/TiC composite coatings with different constitution of Ni-Cr-W-C precursor mixed powders on TiAl alloy substrates have been investigated. The results show that microstructure of the laser fabricated composite coatings possess non-equilibrium microstructure consisting of the matrix of nickel-base solid solution gamma-NiCrAl and reinforcements of TiC, W2C and M23C6 carbides. Higher wear resistance than the original TiAl alloy is achieved in the composite coatings under high-temperature wear test conditions. However, the oxidation resistance of the laser clad gamma/W2C/TiC composite coatings is deceased. The corresponding mechanisms resulting in the above behaviors of the laser clad composite coatings are discussed. (c) 2006 Elsevier B.V. All rights reserved.

Fabricación y reparación de geometrías complejas mediante aporte por laser.

El láser cladding es una tecnología en alza. Mediante la energía de una radiación láser, se crea un baño fundido de material que, combinado con la inyección de material en polvo a través de una boquilla y controlando el movimiento a través de la programación de una plataforma cinemática, ofrece la posibilidad de fabricar una geometría determinada mediante la adición de material. Se trata, sin embargo, de un proceso complejo en el que intervienen gran cantidad de fenómenos físicos y resulta complicado obtener un buen resultado en trayectorias complejas. En el presente trabajo se ha tratado el proceso de fabricación de una geometría compleja tipo álabe de turbina. Para ello, se ha comenzado por llevar a cabo una revisión bibliográfica, posteriormente, se han llevado a cabo una serie de ensayos experimentales para la determinación de parámetros de proceso, y finalmente, se ha desarrollado una estrategia de aporte original para estructuras tipo álabe que permite garantizar la estabilidad del proceso. En base a los resultados satisfactorios obtenidos, se ha concluido que mediante la aplicación de la nueva estrategia es posible la generación de geometrías complejas con alto grado de estabilidad.

Ensayos NDT de piezas fabricadas por Láser Cladding.

[ES]Este trabajo consiste en realizar ensayos NDT de Líquidos Penetrantes sobre unas piezas fabricadas por Láser Cladding. Su objetivo es comprobar la integridad superficial y verificar si se producen discontinuidades superficiales relevantes, de modo que se pueda comprobar la calidad superficial que se obtiene en piezas fabricadas por este proceso.

Microstructure and wear properties of laser clad Fe based amorphous composite coatings

A FeNiSiBV amorphous composite coating was developed by laser cladding of metallic powders on AISI 1020 low carbon steel substrate. The coatings were studied using X-ray diffraction, transmission electron microscopy and scanning electron microscopy. The coating reveals different microstructures along the depth of the coating. The transition zone exhibits good metallurgical bonding between the substrate and the coating. The layer consists of amorphous phase in majority and nanocrystalline phase/crystalline phase in minority. Accompanied with the nanocrystalline phase, the amorphous phase is concentrated in the middle of the coating. The crystalline phase in the coating is identified as Fe2B. A gradient distribution of the microhardness ranges from 1208 HV0.2 to 891 HV0.2 in the coating along the depth. The coating shows higher microhardness and better wear property than the substrate.

Microstructure and hardness characterisation of laser coatings produced with a mixture of AISI 420 stainless steel and Fe-C-Cr-Nb-B-Mo steel alloy powders

Fe-C-Cr-Nb-B-Mo alloy powder and AISI 420 SS powder are deposited using laser cladding to increase the hardness for wear resistant applications. Mixtures from 0 to 100 wt.% were evaluated to understand the effect on the elemental composition, microstructure, phases, and microhardness. The mixture of carbon, boron and niobium in the Fe-C-Cr-Nb-B-Mo alloy powder introduces complex carbides into a Fe-based matrix of AISI 420 SS which increases its hardness. Hardness increased linearly with increasing Fe-C-Cr-Nb-B-Mo alloy, but substantial micro-cracking was observed in the clad layer at additions of 60 wt.% and above; related to a transition from a hypoeutectic alloy containing α-Fe/α' dendrites with an (Fe,Cr)2B and γ-Fe eutectic to primary and continuous carbo-borides M2B (where M represents Fe and Cr) and M23(B,C)6 carbides (where M represents Fe, Cr, Mo) with MC particles (where M represents Nb and Mo). The highest average hardness, for an alloy without micro-cracking, of 952 HV was observed in a 40 wt.% alloy. High stress abrasive scratch testing was conducted on all alloys at various loads (500, 1500, 2500 N). Alloy content was found to have a strong effect on the wear mode and the abrasive wear rate, and the presence of micro-cracks was detrimental to abrasive wear resistance.

激光熔覆MoSi_2涂层的研究

本文用高能激光束熔覆MoSi_2粉末在45钢基体上制备了耐高温结构用涂层，用XRD、SEM、EDAX和显微硬度仪分别对熔覆层的组织结构和硬度进行了研究。试验结果表明，由于基体的稀释作用，涂层的相组成为FeMoSi、Fe_2Si和少量的Mo_5Si_3。涂层组织呈现典型的细小枝晶组织特征，枝晶为FeMoSi领先相，枝晶间为FeMoSi和Fe_2Si两相共晶，组织中无孔隙和裂纹等缺陷存在。Mo，Si，Fe线扫描成分布在涂层-基体界面处均缓慢过渡，基体与涂层发生互扩散，为冶金结合。涂层硬度可达HV_(0.5)845，基体硬度为180，涂层硬度比基体提高3.7倍。

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。

Granulometría de polvos metálicos mediante procesado de imágenes.

[ES]Este documento va a estudiar el desarrollo de un método alternativo de análisis granulométrico de polvos metálicos de láser cladding por procesamiento digital de imágenes. El concepto de tamaño de partícula, la cual, normalmente, tiene forma irregular, es muy importante de cara a controlar de manera fiable ciertas fases de procesos industriales. Un buen control del tamaño de partícula y de su forma repercute en una mayor calidad del proceso y del producto final. Tradicionalmente, el análisis granulométrico en procesos industriales se ha realizado por el método de tamizado, un método mecánico que consiste en que la muestra de polvo atraviese sucesivamente mallas con orificios progresivamente decrecientes. En los últimos años, los avances tecnológicos han revolucionado los procesos industriales. En concreto, campos como la visión artificial han adquirido gran presencia por tener como ventajas una alta velocidad de operación, gran capacidad de aumento, funcionamiento las 24 horas del día o la repetitividad de las medidas. Su objetivo es normalmente comprobar la conformidad de una pieza de acuerdo a ciertos requisitos especificados. Se propone un método adaptado a las nuevas tecnologías. En concreto, se busca ganar en información, fiabilidad, rapidez y repetitividad respecto a los métodos granulométricos clásicos. Se van a desarrollar algoritmos de análisis haciendo uso de herramientas informáticas y el software comercial Matlab. En el análisis, se van a crear indicadores que permitan caracterizar la muestra con la mayor fiabilidad posible. Finalmente, se van a aplicar los métodos desarrollados en muestras de polvo reales y diversas para comprobar el buen funcionamiento del método.

Diseño y fabricación de una boquilla coaxial de aporte de material para un láser.

[ES]Este trabajo de fin de grado tiene como objetivo principal el diseño y la posterior fabricación de una boquilla coaxial que aporte material de cobertura para “laser cladding”. Para ello se utilizarán programas de diseño gráfico para hacer la geometría y programas de elementos finitos para simular el comportamiento del polvo y el gas dentro de la boquilla.

Diseño y fabricación de un electrodo para electroerosión por penetración mediante fabricación aditiva.

[ES]Este trabajo pretende dar solución a la fabricación de los electrodos utilizados en el proceso de la electroerosión, los cuales presentan numerosos requisitos a los que los electrodos actuales no dan respuesta. Por ello, se propone utilizar un material de bajo coste como núcleo y recubrirlo con una fina capa de cobre mediante laser cladding. De esta forma, se reduce el coste del electrodo manteniendo sus propiedades y se posibilita la creación de geometrías complejas.

基于神经网络的激光熔覆高度预测

激光成形过程中,对熔覆高度进行实时检测,从而实现熔覆高度闭环控制是成形高质量零件的保证。激光成形过程是一个多参数耦合的非线性过程,大量激光参数对成形熔覆表面质量具有重要影响。在分析激光参数对熔覆高度影响的基础上,建立利用激光工艺参数预测熔覆高度的误差反向传播(Backpropagation,BP)神经网络模型,完成了网络算法设计。通过激光成形试验采集样本,利用训练样本对所建立的网络进行训练,完成网络输入输出高度映射关系,并利用测试样本对所训练的网络进行检验。仿真试验表明,神经网络熔覆高度预测模型具有很高的精度,验证了该预测模型在理论和实践上的可行性与有效性。神经网络熔覆高度预测模型为实现激光加工过程熔覆高度实时预测与闭环控制打下基础,对提高成形产品质量具有重要意义。