Laser shock peening has been widely studied and pioneeringly applied in aerospace industry as a life-extension technology for structured mechanical components. However, in other promising fields such as nuclear power industry, little has been studied concerning such critical issues as long-distance transmission of the laser beam by optical fiber and optimized parameters of typically low pulse energy with micrometer-sized beam spots. In such scenario, the overlapping rate between adjacent small spots plays a critical role in obtaining homogenous residual stress and surface morphology. In this study, a three-dimensional finite element model in AISI 420 martensitic stainless steel has been developed to correlate the residual stress as well as surface morphology with varying overlapping rates. Multiple laser spots are loaded with VDLOAD user subroutine in Abaqus. The residual stress distribution is analyzed with respects of laser shocking and in-depth planes. And the surface morphology is evaluated in terms of depression depth as well as surface roughness. Combined results suggest that the overlapping rate of 61% as an optimized value, which can be used as a basis for future experimental studies and industrial applications.
Pores and weak bonding are the inherently drawbacks for thermally sprayed coating. Laser beam is an attractive approach to remelt thermal spray coating for obtaining fully dense coating with metallurgical bonding with substrate. However, defects of holes or cracks are highly inevitable with unmatching remelting processing parameters. In this work, a thermally sprayed Cr3C2-NiCr cermet coating by high velocity oxygen fuel spraying was post-processed by laser remelting with a series of varying beam energy densities from 37.5 J/mm2 to 225 J/mm2. The defect evolution was investigated by both experimental and numerical simulation methods. Large holes and through-thickness cracks were typical defects observed in the remelt coating by optical microscopy. The experimental results show that remelting-induced defects evolve into three stages with laser energy density. The effect of energy density on remelt structure was further verified with the temperature field by numerical simulation with ABAQUS code. The stress field interpreted the crack formation at periodical formation sites. The results on the defect evolution shed light on obtaining functional coatings for industrial applications.
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