et al.. Laser cladding of Ni based powder on a Cu-Ni-Al glassmold: Influence of the process parameters on bonding quality and coating geometry. a b s t r a c tLaser cladding of a Ni based powder on cupro-nickel-aluminum (Cu-Ni-Al) substrate was performed with a 4 kW continuous laser. The Cu-Ni-Al alloy is used for its thermal properties in glass mold industry. The role of the Ni based alloy clad is to protect the mold without affecting its thermal properties by limiting the heat-affected zone. The objective of this research is to produce a well bonded Ni based melted powder without pores or cracks and with a very small dilution zone on a non-planar surface (curved section). The impact of the process parameters such as laser power, scanning speed and powder feeding rate on the coating geometry was investigated with an experimental design technique analysis using the ANOVA (Analysis of variance) method. It was used to determine and represent the influence of each process parameter on the coating geometry (width, height) and the bonding quality. This ANOVA analysis led to a parameter combination to optimize the bonding quality between the Ni coating and the Cu-Ni-Al substrate taking into account the industrial geometrical constraints. More, an analytical calculation allowed to estimate the power necessary for bonding as a function of laser scanning speed and powder feeding rate.
In glass industry, laser cladding is an innovative surfacing technique allowing to deposit a layer of nickel to protect glass mold against corrosion, abrasion and thermal fatigue. This method (powder fusion by projection), well known in additive manufacturing represents a real technological leap for the glass industry. But during laser cladding of Ni-based powder on gray cast iron, cracks can be observed for some process conditions. These cracks are often due to the Heat Affected Zone that creates structural stresses linked to the development of a martensitic structure in the ferritic matrix of the lamellar graphite cast iron. The aim of this work is to observe the impact of laser cladding (without substrate pre-heating usually employed to limit cracking) on the coating behavior but also on the flake-graphite cast iron substrates. The microstructure and the mechanical properties were studied (SEM and microanalysis, microhardness) around the interface cladding/substrate. Also, the impact of the processing parameters (power P (1500-2300 W), scanning speed v (2.5-10 mm/s) and powder feeding rate PFR (24.5-32.5 g/min) was studied by using the ANOVA (ANalysis Of VAriance) technique. It has been observed that laser cladding on graphite cast iron is possible without cracks by limiting the linear energy induced by the process. Also, an optimization of the processing parameters (P, v, PFR) in order to obtain the industrial expected geometry of the coating has been proposed.
Laser cladding of a Ni based powder on Cu-Ni-Al or cast iron was performed with a 4kW continuous Nd: YAG laser. The Cu-Ni-Al and cast-iron substrates are used for their thermal properties in glass mold industry. But the issue of these materials is their lack of resistance on corrosion and abrasion. The role of the Ni based alloy is to protect the mold without affecting its thermal properties (Heat Affected Zone (HAZ)). The purpose of this research is to produce a well bonded Ni based melted powder without pores or cracks on a non-planar surface (curvilinear section). An investigation of the impact of the processing parameters, power (1500-3200 W), scanning speed (2.5-10 mm/s) and powder feeding rate (24.5-32.5 g/min) on the bonding quality, the porosity propagation and HAZ appearance is performed. The used methods are neutronography, Scanning Electron Microscopy, Energy Dispersive Spectroscopy and Electron BackScatter Diffraction (EBSD). These multi-scale techniques are obviously complementary. Neutronography is a well-adapted non-destructive method to observe the porosity in the volume thanks to the contrast between materials. EBSD analysis allows us to analyze the microstructural evolution of the coating notably by observing the dendrites growth. This same method also permits to observe the HAZ nature according to the laser cladding parameters. Those methods allowed to optimize the processing parameters in a way to obtain perfect bonding, to avoid porosity propagation and to limit the HAZ emergence.
Laser metal deposition (LMD) is an alternative method to other cladding techniques such as Plasma Transfer Arc (PTA) or blowtorch for surface treatment in the glass industry. It aims to produce dense, high-quality coatings on a non-planar surface without affecting its thermal and mechanical properties. In this study, Ni-based coatings were coated onto Cu-Ni-Al substrate using a 3 JET nozzle technique. During laser cladding, good metallurgical bonding is necessary to ensure the further surfacing process technique. A microstructural analysis was conducted, and the mechanical properties were then evaluated with microhardness analysis to link process parameters to coating bonding quality. A calculation of the power attenuation attempts to explain the impact of the powder distribution on the bonding. This work revealed that a chemical dilution zone exists between coating and substrate and is necessary for perfect metallurgical bonding. The heterogeneous bonding, observed through the section, along the curved interface coating/substrate, has been linked to the Gaussian distribution of the powder that attenuates the input power. The attenuated power was measured all along the interface.
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