Real-Time Quality Monitoring of Laser Cladding Process on Rail Steel by an Infrared Camera

Srisungsitthisunti, Pornsak; Kaewprachum, Boonrit; Yang, Zhigang; Gao, Guhui

doi:10.3390/met12050825

Cited by 10 publications

(6 citation statements)

References 25 publications

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“…One such method that has been explored is the single-factor experiment, which analyzes the individual impact of variables. The methodology reveals that increasing laser power directly affects the laser spot, melt pool area, cladding height, and width increase [22,23]. Additionally, it has been observed that the cladding width, depth, and height tend to decrease as the laser beam diameter increases [24], and that the cladding depth decreases with an increase in gas supply [25].…”

Section: Introductionmentioning

confidence: 94%

Microstructural characterization martensitic stainless-steel coatings deposited by laser metal deposition

Rodriguez,

Silva,

Torres

et al. 2024

Preprint

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Additive manufacturing (AM) technology, characterized by layer-by-layer deposition, is emerging as an alternative to produce parts, typically with complex geometries, and has recently become an option for mass production. This technology has been adopted by several industries due to its ability to save material resources and processing time. In addition, it could lead to component weight reduction, design optimization and the development of new materials. Among the AM processes, laser metal deposition (LMD) offers a high build rate and allows for larger deposition volumes compared to powder bed-based technology, resulting in lower manufacturing costs. Several industries, such as aerospace and defense, have focused on the use of LMD due to the opportunities for cost savings, increased productivity, and repair of large mechanical components. In particular, LMD could be used in the aerospace industry for the manufacture and repair of engines, turbines and propulsion systems, space shuttles, communications satellites. Currently, several types of metals, including important engineering materials such as steel, aluminum, and titanium, can be used to produce parts with high levels of precision and excellent properties. The use of martensitic stainless steels has increased in the automotive, aerospace and defense industries, mainly due to their mechanical properties such as high flow resistance and reasonable ductility. However, the deposition of martensitic stainless steels using LMD presents challenges in the selection of parameters, morphology configurations and phase evolutions to ensure the required mechanical properties. The objective of the present work was to evaluate the deposition parameters for laser cladding using LMD with martensitic stainless steel AISI 431 powder. In addition, morphological aspects were analyzed. The microstructural evolution was assessed using optical and electron microscopy. The results show dilution values between 10 and 27% were found for power values between 1400 and 1600 W and laser beam velocities of 9, 14 and 16 mm/s. Microstructural characterization revealed martensite and ferrite phases in the depositions. Several factors influence the geometric and microstructural characteristics of the laser cladded deposits, such as the morphology and size distribution of the filler particles, the chemical composition of the materials, the flow rate and deposition method of the filler, and the power and beam speed of the laser.

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Section: Introductionmentioning

confidence: 94%

Microstructural characterization martensitic stainless-steel coatings deposited by laser metal deposition

Rodriguez,

Silva,

Torres

et al. 2024

Preprint

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“…Among them, the more studied parameters are the laser power, powder feeding rate, and scanning speed [55][56][57][58]. Pornsak et al [59] observed the cladding process in real time by using an infrared camera with image analysis software. The results showed that the laser spot, melt pool area, cladding height, and width all increased with increasing laser power.…”

Section: Single-factor Experimentsmentioning

confidence: 99%

“…(a) Effect of different laser powers on the melt pool. Reprinted from [59]. (b) Fracture toughness and fracture energy of coatings at different laser powers.…”

Section: Figurementioning

confidence: 99%

An Overview of Technological Parameter Optimization in the Case of Laser Cladding

et al. 2023

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This review examines the methods used to optimize the process parameters of laser cladding, including traditional optimization algorithms such as single-factor, regression analysis, response surface, and Taguchi, as well as intelligent system optimization algorithms such as neural network models, genetic algorithms, support vector machines, the new non-dominance ranking genetic algorithm II, and particle swarm algorithms. The advantages and disadvantages of various laser cladding process optimization methods are analyzed and summarized. Finally, the development trend of optimization methods in the field of laser cladding is summarized and predicted. It is believed that the result would serve as a foundation for future studies on the preparation of high-quality laser cladding coatings.

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“…However, it is difficult to achieve on-line monitoring of all influencing factors, resulting in the failure to accurately monitor the coating quality. At present, scholars have carried out much research on the on-line monitoring technology of coating quality in the laser cladding process [7][8][9].…”

Section: Introductionmentioning

confidence: 99%

“…𝐿 * ℎ * 𝑠𝑖𝑛𝛽 𝑙 * 𝑠𝑖𝑛𝛼 ℎ * 𝑠𝑖𝑛 𝛼 𝛽 (7) In Expression (7), the optical structure parameters L, l, α, and β are constants in actual applications, and the imaging spot displacement h can be calculated by the measurement system. Therefore, the height z of all points on the coating surface can be calculated.…”

mentioning

confidence: 99%

Research of On-Line Monitoring Technology Based on Laser Triangulation for Surface Morphology of Extreme High-Speed Laser Cladding Coating

Wang

Guo

et al. 2023

Coatings

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This work aims to develop a novel method for on-line monitoring of coating quality during the Extreme High-speed Laser Cladding (EHLA) process. JG-11 coating was prepared by EHLA, and microstructure, microhardness, corrosion performance, and scratch resistance were investigated. To analyze the influences of fluctuations in processing parameters on coating quality, a single-factor experiment scheme was designed and an on-line monitoring system based on laser triangulation was built. Furthermore, a new forming method for the surface profile of EHLA coating was proposed, and a new comprehensive evaluation index of surface morphology was accordingly designed. Benefitting from the extremely high cooling rate, EHLA JG-11 coating had fine grains, high hardness, and better corrosion resistance and scratch resistance than those of Electroplating Hard Chromium (EHC). The results revealed that the surface morphologies presented different characteristics due to the fluctuations of process parameters, such as high surface flatness, deep pits, small peaks, poor directionality, etc. The comprehensive evaluation index composed of Sa, Ssk, and Str could effectively characterize the surface morphology of EHLA coating, which proved that the monitoring system and evaluation method could realize on-line monitoring of the process parameters during the EHLA process.

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Real-Time Quality Monitoring of Laser Cladding Process on Rail Steel by an Infrared Camera

Cited by 10 publications

References 25 publications

Microstructural characterization martensitic stainless-steel coatings deposited by laser metal deposition

Microstructural characterization martensitic stainless-steel coatings deposited by laser metal deposition

An Overview of Technological Parameter Optimization in the Case of Laser Cladding

Research of On-Line Monitoring Technology Based on Laser Triangulation for Surface Morphology of Extreme High-Speed Laser Cladding Coating

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