Laser cladding technique for erosive wear applications: a review

Abstract

Slurry erosion is a serious menace in most of the hydro machine components all around the globe. Slurry erosion is accountable for heavy economic losses. However, some counter measures are being taken to mitigate the effect of sand particles passing through hydro-machine parts and research is also underway to improve the component surface by applying different surface coatings. Laser cladding is a surface deposition process that is used to achieve very good metallurgical bonding with minimum porosity as compared to other surface coating techniques. In this research paper, an attempt has been made to compile the literature related to laser cladding technology, its applications, process parameters, coating materials and their effectiveness to bestow solutions to various types of surface degradation with special emphasis on slurry erosion problems. This paper will serve as a reference for the researchers working in the area of slurry erosion prevention.Erosion is described as wear induced by solid particles hitting a surface, transferred via a gas flow or entertained in a fluid streaming medium [16]. The impinging angle of the particles and relative velocity determines the abrasive wear on a surface [17]. Hydro abrasive erosion depends upon several parameters such as size of sand, hardness, concentration, shape, quantity, and velocity, in most cases minimizing the impact energy of the particles by monitoring the parameters mentioned or indirectly. Despite this, enormous surface destruction to hydroelectric devices and structures occurs at any stage at a sufficiently elevated velocity, causing scratching and removal of material [18]. It has been learned that because of their excellent corrosion characteristics and acceptable resistance to strong particle erosion, in hydroelectric power plants stainless steels are widely used [16]. Bitter [19] suggested two erosion wear theories: cutting and deformation, according to him, the cutting wear is triggered by the particle velocity element parallel to the target surface, whereas the deformation wear is accountable for the normal component of the velocity. Some researchers [20-24] indicated that hardness of the target material or hardness of the impacting solid particles was dominant for wear of target surface. Wang and Yang [25] noted that a dominant function in the erosion process is the surface hardening of metals. The worn surfaces were analysed by scanning electron microscope and different wear processes such as micro-ploughing, lip formation, platelet, tiny indentation craters, and micro-cracking were described. It was reported that the depletion of materials such as metals and alloys was produced by the micro-cutting and microploughing of strong particles for ductile materials. The crack coalescence results in the removal of large-scale components for brittle materials.Material degradation by the dint of slurry erosion relies on myriad variables that can be classified into three primary groups: the first one associated with fluid flow circumstances (flow speed, partic...

Tool and Die Making, Surface Treatment, and Repair by Laser-based Additive Processes

“…DED-p (or LMD-p or LC), even called Blown Powder Technology [40], can be used to improve a tool's operational performance. In several investigations, this technology is used to coat the tool (die or mold made conventionally in wrought steel) with: a cobalt (Co) based Stellite alloy (Co, 20-30 wt% chromium (Cr), 4-18 wt% tungsten (W) or molybdenum (Mo), and 0.25-3 wt% carbon (C)) for resistance to high temperature, oxidation, wear, and corrosion, and for high hardness [41,42]. nickel (Ni) based hard facing alloys (NiSiB, NiCrSiB, Inconel 625 (NiCrSiBFeC) etc.)…”

“…nickel (Ni) based hard facing alloys (NiSiB, NiCrSiB, Inconel 625 (NiCrSiBFeC) etc.) to accomplish high toughness and thermal and corrosion resistance [42,43]. iron (Fe) based alloys (316 stainless steel, Fe-Cr-Si-B alloy, Crucible Particle Metallurgy (CPM) steel) for enhanced abrasive wear and corrosion resistance (and reduction of the tool costs) [42][43][44][45].…”

“…), or oxides (Al2O3, etc.) to improve the wear resistance [42,43]. self-lubricating materials such as soft metals (gold, silver, tin etc.…”

Numerical Simulation of Convex Shape Beam Spot on Stress Field of Plasma-sprayed MCrAlY Coating During Laser Cladding Process

“…Laser cladding refers to radiating high-energy-density laser beams on the surface of base material and forming a layer of materials with special physical, chemical or mechanical properties on it through rapid melting, expansion and solidi cation. In comparison with other surface machining technologies, the laser cladding technology integrates the merits of broad scope of application, strong practicability and exible application, so it has aroused extensive attention and attracted great importance and has been widely used [1][2][3][4][5][6][7][8]. At present the major problem in laser cladding is high coating brittleness and great cracking tendency [9][10][11][12][13][14][15][16], which considerably restricts its scope of application in key components, so cracking inhibition in the laser cladding is of great realistic signi cance to the application of the laser cladding technology in production.…”

Slurry Erosion–Corrosion Characteristics of As-Built Ti-6Al-4V Manufactured by Selective Laser Melting

“…Surface coatings and heat treatments have been observed to be common practices to improve both surface hardening and strength. It was also reported that the Ti6Al4V alloy has ductile material erosion behavior with maximum erosive wear rate at an impact angle of around 20–30° [ 12 , 27 , 28 , 29 ].…”