Process planning and optimisation of laser cladding considering hydrodynamics and heat dissipation geometry of parts

Niz'ev, Vladimir G; Khomenko, M. D.; Mirzade, F. Kh.

doi:10.1070/qel16708

Cited by 8 publications

(3 citation statements)

References 16 publications

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“…When the laser power is too high, the deformation of thin-walled parts increases and the laser can easily burn through the parts; however, when the laser power is too low, a bright white band cannot be formed in the bonding area between the substrate and the alloy material, and the quality requirements of the cladding cannot be met [9]. Many factors affect the quality of thin-walled parts, and determining how to adjust these factors to ensure the quality of the cladding layer and control the deformation of the substrate has become the key to the success of the repair of thin-walled parts [10][11][12]. When repairing thin-walled parts, a large temperature gradient occurs between the cladding layer and the substrate, and there is a difference between the coefficients of thermal expansion of the substrate and the alloy powder; this leads to differences in the thermal expansion and cooling shrinkage of each local area, and cladding stress will occur in the cladding layer [13].…”

Section: Introductionmentioning

confidence: 99%

Study on the Deformation Control and Microstructures of Thin-Walled Parts Repaired by Laser Cladding

Huang

2020

Coatings

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To reduce the deformation and improve the quality of thin-walled parts repaired by laser cladding, a three-factor, three-level orthogonal experimental scheme was employed to clad Ni60 powder on thin-walled parts with a thickness of 3.5 mm. To measure the deformation of the thin-walled parts, a method of combining the meshing of the backs of the thin-walled parts and fixing one end of the parts during cladding was used. The effects of the powder feed rate, laser power, and scanning speed on the deformation of the thin-walled parts were studied via visual analysis and analysis of variance, and the process parameters that resulted in the minimum deformation were determined. The deformation process of the thin-walled parts and the causes of cladding stress were also studied, and the microstructure of the cladding layer with the minimum deformation was analyzed via scanning electron microscopy (SEM). The results reveal that the deformation of the thin-walled parts increased with the increase of laser power. The increases of the scanning speed and powder feed rate were found to reduce the deformation of thin-walled parts; the laser power was found to have a significant effect, and the powder feed rate was found to have no significant effect, on the deformation of thin-walled parts. The order of the influence of factors on the deformation of thin-walled parts from greatest to least was determined to be as follows: laser power > scanning speed > powder feed rate. The optimal parameters to obtain the minimum deformation and good metallurgical bonding of thin-walled parts were found to be a powder feed rate of 1.4 r/min, a laser power of 1100 W, and a scanning speed of 8 mm/s. From the bottom to the top, the crystal structure of the coating with the minimum deformation was found to be coarse dendrite, dendritic crystal, and equiaxed crystal.

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Section: Introductionmentioning

confidence: 99%

Study on the Deformation Control and Microstructures of Thin-Walled Parts Repaired by Laser Cladding

Huang

2020

Coatings

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“…V.G. et al [ 21 ] developed a hydrodynamic model based on the open computational fluid dynamics package OpenFoam, which took the heat dissipation geometry into account. However, it is inconvenient to understand the nucleation mechanism and evolution law of porosities during solidification.…”

Section: Introductionmentioning

confidence: 99%

Investigation on the Microporosity Formation of IN718 Alloy during Laser Cladding Based on Cellular Automaton

et al. 2021

Materials

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Porosity is one of the most common defects in the laser cladding of Inconel 718 (IN718) alloy, which can reduce the strength and fatigue performance of the components. However, the dynamic formation of microporosity is challenging to observe through experiments directly. In order to explore the formation mechanism of porosities and dynamically reproduce the competitive growth between porosities and dendrite, a multi-scale numerical model was adopted, combined with a cellular automaton (CA) and finite element method (FEM). The decentered square algorithm was adopted to eliminate crystallographic anisotropy and simulate dendrite growth in different orientations. Afterward, based on the formation mechanism of microporosity during solidification, equiaxed and columnar dendrites with porosities were simulated, respectively. Dendrite morphology, porosity morphology, and distribution of solute concentration were obtained during the solidification process. The simulation results were reasonably compared with experimental data. The simulation results of the equiaxed crystal region are close to the experimental data, but the columnar crystal region has a relative error. Finally, the interaction effects of porosities and dendrites under different environmental conditions were discussed. The results suggested that with the increase in the cooling rate, the quantity of porosity nucleation increased and the porosity decreased.

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“…It is also light in weight and corrosion resistant. Considering the laser additive manufacturing (AM) process the relationships between the deposition parameters, microstructure, and mechanical properties of that alloy have been studied [11] primarily with the use of unit tracks deposition onto a massive substrate [12] or the fabrication of simple geometric solid bodies. It was found improved behaviour when compared with their wrought counterparts [13] primarily due to fact that the deposited material undergoes rapid cooling enabling some grain refinements.…”

Section: Introductionmentioning

confidence: 99%

Ti6Al4V Thin Walls Production using Laser Directed Energy Deposition (L-DED) Process

Rios

Mariani²,

Coelho

2021

IJEMM

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One of the main applications of Directed Energy Deposition (DED) is the production of thin-wall structures, where it has significant advantages over traditional milling and machining techniques, or even welded analogues. These kinds of structures are frequently employed in aerospace components, field where titanium alloys have a primary role to play. Amongst them, the most employed is the Ti6Al4V with an alpha + beta alloy containing 6% Aluminium (Al) and 4% Vanadium (V). It has an excellent combination of strength and toughness along with excellent corrosion resistance. For the study hereby, thin-wall structures were constructed employing a Laser Directed Energy Deposition machine (L-DED), working with powder material. Analyse identified some microstructural and mechanical characteristics, thorough metallographic study, wear test (micro-adhesive) and micro hardness test. Finding a grain refined structure with competitive mechanical properties compared to materials manufactured by traditional processes. Results positioning DED as an attractive manufacturing technology, with a huge potential to improve costs and material usage, besides almost no restriction on component shape.

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Process planning and optimisation of laser cladding considering hydrodynamics and heat dissipation geometry of parts

Cited by 8 publications

References 16 publications

Study on the Deformation Control and Microstructures of Thin-Walled Parts Repaired by Laser Cladding

Study on the Deformation Control and Microstructures of Thin-Walled Parts Repaired by Laser Cladding

Investigation on the Microporosity Formation of IN718 Alloy during Laser Cladding Based on Cellular Automaton

Ti6Al4V Thin Walls Production using Laser Directed Energy Deposition (L-DED) Process

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