施晓帅,姜芙林,王玉玲,杨发展,杨勇,梁鹏,马保山.基于响应面法的激光熔覆3540Fe涂层形貌及质量预测研究[J].表面技术,2022,51(12):392-405.
SHI Xiao-shuai,JIANG Fu-lin,WANG Yu-ling,YANG Fa-zhan,YANG Yong,LIANG Peng,MA Bao-shan.Morphology and Quality Prediction of Laser Cladding 3540Fe Coating Based on Response Surface Method[J].Surface Technology,2022,51(12):392-405 |
| 基于响应面法的激光熔覆3540Fe涂层形貌及质量预测研究 |
| Morphology and Quality Prediction of Laser Cladding 3540Fe Coating Based on Response Surface Method |
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| DOI：10.16490/j.cnki.issn.1001-3660.2022.12.040 |
| 中文关键词: 激光熔覆 熔覆层形貌控制 工艺参数 3540Fe 响应面法 预测模型 |
| 英文关键词:laser cladding cladding layer morphology control process parameters 3540Fe response surface method prediction model |
| 基金项目:山东省重点研发计划资助项目(2019GNC106102);山东省自然科学基金资助项目(ZR2019MEE059、ZR2021ME198);高等学校学科创新引智计划资助(D21017) |
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| Author | Institution |
| SHI Xiao-shuai | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| JIANG Fu-lin | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| WANG Yu-ling | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| YANG Fa-zhan | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| YANG Yong | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| LIANG Peng | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
| MA Bao-shan | School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao 266520, China |
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| 中文摘要: |
| 目的 实现激光熔覆3540Fe合金涂层几何形貌的精确控制。方法 基于响应面法设计了在不同的激光工艺参数下42CrMo钢表面激光熔覆3540Fe合金的试验，以激光功率、光斑直径、扫描速度为影响因素，熔覆层宽度、高度、熔池深度、熔覆层宽高比、显微硬度以及稀释率为响应目标，建立了熔覆层形貌的预测模型，以熔覆层显微硬度、宽高比作为优化条件对预测模型进行了实验验证。结果 激光功率与熔池深度和熔覆层稀释率成正比，熔覆层宽度、高度、宽高比随激光功率的增大表现为先升高后降低，熔覆层显微硬度与激光功率的关系呈负相关。扫描速度与熔覆层宽度、高度呈负相关性，与熔覆层宽高比、显微硬度成正比，对熔池深度和熔覆层稀释率的影响并不显著。光斑直径与熔池深度和稀释率呈负相关性，熔覆层高度随光斑直径的增大表现为先增大后减小，而宽高比表现为先减小后增大的趋势，光斑直径对熔覆层显微硬度的影响并不显著。通过对预测模型进行实验验证发现，宽高比、稀释率、显微硬度的误差分别为7.14%、5.70%、2.74%。结论 利用响应面法建立的3540Fe合金熔覆层形貌预测模型精确程度较高，能够实现对3540Fe合金熔覆层几何形貌的准确预测，为熔覆层形貌的精确控制提供了理论依据。 |
| 英文摘要: |
| Laser cladding technology is an advanced surface modification technology which can significantly improve the properties of metal surface such as wear resistance, corrosion resistance and heat resistance. The step effect is caused by the processing mode of laser cladding technology, which can not meet the actual requirements of the cladding layer. In this paper, the influence of laser process parameters on the cladding layer morphology and quality is studied, and the related prediction model is established, which has certain significance to realize the precise control of cladding layer morphology. According to the Box-Behnken Design (BBD) experiment scheme in Design-Expert 11 software, a three-factor and three-level experiment was designed. Laser power (A), spot diameter (B) and scanning speed (C) were selected as the influencing factors. The value range of laser power P was 1.6 kW, 1.7 kW and 1.8 kW, spot diameter was 3 mm, 4 mm and 5 mm, and scanning speed was 3 mm/s, 4 mm/s and 5 mm/s. Each factor was coded with ‒1, 0 and 1 as the factor level. The cladding layer width (W), height (H), pool depth (Hf) and width to height ratio (λ) were selected to characterize the cladding layer morphology, and the coating quality was characterized by microhardness (Microhardness) and dilution ratio (η). Fifteen groups of laser process parameters compound experiments were designed. 42CrMo steel was used as the substrate, and 3540Fe iron base alloy powder with mass fraction ratio of 1.2%CeO2 was used as cladding powder. Before the experiment, the base material was polished with 150-600 mesh sandpaper and cleaned with anhydrous ethanol. Then, the fully mixed powder was laid on the base material with anhydrous ethanol and the laying thickness was 1mm. Then, the drying treatment was carried out, the drying chamber temperature is set to 120 ℃ and lasts for 120 min argon was used as the shielding gas in the experiment, and the shielding gas flow was 10 L/min. After the experiment, the sample was machined into a size of 20 mm×15 mm×10 mm by WEDM. The section of the cladding layer was polished, and the hardness was measured by Vickers Microhardness tester (HV-1000). The sample was corroded with a corrosive solution (HCl∶C2H6O=1∶3) for 15 s. The section morphology of the cladding layer was observed and the morphological characteristic data were measured by optical microscope. The effects of laser processing parameters on the morphology and quality of cladding layer are analyzed by response surface method as follows:laser power has the largest effect on the width of cladding layer, followed by spot diameter; scanning speed has the greatest influence on the height of cladding layer, followed by laser power. Spot diameter has the greatest influence on the molten pool depth, followed by laser power. Scanning speed has the greatest influence on aspect ratio. The effects of laser processing parameters on the quality of cladding layer are as follows:laser power has the greatest influence on the microhardness of cladding layer, followed by scanning speed; spot diameter has the greatest influence on dilution rate, followed by laser power. The micro-hardness and width-to-height ratio of cladding layer were selected as constraint conditions to verify the prediction model. The results showed that the errors of width-to-height ratio, dilution ratio and micro-hardness were 7.14%, 5.70% and 2.74%, respectively. The model has high accuracy and can accurately predict the cladding layer's geometric morphology. |
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