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],51(12):392-405
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
KeyWord:laser cladding  cladding layer morphology control  process parameters  3540Fe  response surface method  prediction model
                    
AuthorInstitution
SHI Xiao-shuai School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China
JIANG Fu-lin School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China
WANG Yu-ling School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China
YANG Fa-zhan School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China
YANG Yong School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China
LIANG Peng School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China
MA Bao-shan School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China
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Abstract:
      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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