Thermo-Mechanical Coupling Numerical Simulation for Extreme High-Speed Laser Cladding of Chrome-Iron Alloy

Abstract

With the aim to improve cladding coating quality and prevent cracking, this paper established an extreme high-speed laser cladding thermo-mechanical coupling simulation model to study the evolution of the temperature field and the residual stress distribution. Process parameters that impacted the macroscopic morphology of single-pass coatings were investigated. Numerical calculations and temperature field simulations were performed based on the process parameter data to validate the effects of the temperature gradient and cooling rate on the coating structure and the residual stress distribution. The results showed that a good coating quality could be achieved using a laser power of 2400 W, a cladding speed of 20 m/min, and a powder feeding rate of 20.32 g/min. The coatings’ cross-sectional morphology corresponded well with the temperature distribution predicted by the numerical modeling of the melt pool. The microstructure of the molten coatings was affected by the temperature gradient and the cooling rate, which varied greatly from the bottom to the middle to the top. Maximum residual stress appeared between the bonding region of the coatings and the substrate, and the coatings themselves had significant residual stress in the form of tensile strains, that were mostly distributed in the direction of the laser cladding.

Effect of WC Content on the Wear and Corrosion Properties of Oscillating Laser-Cladding-Produced Nickel-Based Coating

“…It is worth noting that the friction coefficients of the specimens may experience sudden changes in some cases, and the friction coefficients of coatings often show peaks or valleys over time. This is because during the friction and wear process of the coatings, the complex and uneven distribution of the coating composition leads to different local microstructures and friction coefficients [40]. Therefore, when the Si 3 N 4 ball friction passes through these regions, sudden changes in the friction coefficient occur.…”

Engineering Process Optimization and Quality Stability Control of High-Speed Laser Cladding Coatings Based on AHP-FCE

“…With the rapid increase of laser beam scanning speed, the high overlap between paths and the two-stage melting process before and after powder material enters the molten pool are common in high-speed laser cladding coatings [5][6][7]. As a result, the coating quality, including its forming quality, near-surface microstructure, and surface properties, is significantly different from those produced using traditional laser cladding [8][9][10].…”

Numerical Simulation Analysis of Temperature Distribution of NbC-Reinforced Ti-Based Composite Coating by Laser Cladding

“…The three-dimensional model is created by numerical simulation to simulate the laser cladding process under different processing parameters [28]. Thereafter, the simulation results are analyzed to determine the reasonable processing parameters and finally experiment [29,30]. This method is beneficial to reduce time and cost consumption.…”