目的 利用激光熔覆技术提高齿轮抗胶合承载能力及其在齿面胶合损伤修复中应用的可行性。方法 分别以18CrNiMo7-6齿轮钢调质试样、渗碳试样和渗碳后胶合损伤试样为基体,采用MobiMRO-2激光熔覆设备在圆盘试样外圆周表面制备NiCr20-3%ZrO2-1%MoS2（质量分数）激光熔覆层。分析了熔覆合金层微观组织以及激光熔覆过程对不同基体材料微观组织性能的影响,并通过双盘式滚动接触胶合损伤模拟试验,对比了不同熔覆试样和未熔覆渗碳试样的胶合承载能力及其损伤行为。结果 制备的激光熔覆合金层主要由枝晶组织、胞晶组织和不规则颗粒物组成,其熔覆层厚度约为1.2 mm,硬度为690~730HV0.1,与渗碳齿面硬化层相当;在激光熔覆过程中,试样热影响区组织发生显著变化,包括马氏体、贝氏体及球化组织等;与未熔覆试样相比,调质基体熔覆、渗碳基体熔覆和损伤修复试样的抗胶合承载能力分别提升94.4%、61.3%和50.7%,其提升效果主要来源于激光熔覆后材料硬度的提升和激光熔覆层的自润滑效果;胶合失效机制分析表明,熔覆层通过改变裂纹萌生与扩展路径,显著提高了临界失效载荷。结论 本研究证实了激光熔覆技术可有效提升齿轮的抗胶合性能,并成功实现了对胶合损伤齿面的高性能修复,为齿轮的表面强化与损伤修复提供了实验依据与理论支持。
Abstract
Scuffing is a rapid and severe form of failure commonly found in high-speed and heavy-duty gear transmission systems. Improving the scuffing load capacity has become a key technical challenge to ensure the service reliability of high-power-density gear systems. Currently, enhancing gear surface resistance to both fatigue and scuffing through surface modification technology represents a major approach for manufacturing high-performance and highly reliable gears. Laser cladding is an emerging technology for surface repair and additive manufacturing. Due to its many advantages, it has been widely used to improve the performance of critical components in industries such as automotive, mold-making, and railways. While most studies on laser cladding repair for gears focus on tempered gears, this work targets carburized and hardened gears which are the most commonly used type in heavy-duty industrial gear drives. To explore the feasibility of using laser cladding to improve scuffing resistance and repair damaged tooth surfaces, 18CrNiMo7-6 gear steel was selected as the base material. Three types of substrates were prepared: tempered, carburized, and carburized samples with pre-induced scuffing damage. A NiCr20-3%ZrO2-1%MoS2 laser-cladded coating was fabricated on the outer circumferential surface of disk samples by a MobiMRO-2 laser cladding system with synchronous powder feeding. The cladded samples were then machined to meet the requirements for subsequent scuffing tests. After machining, the cladded coating exhibited a thickness of approximately 1 mm and a surface roughness of Ra = 0.3 μm. Subsequent scuffing tests were conducted on an MJP-30A rolling contact test rig with a step-wise loading method, with the load increasing by 300 N at each stage. The test conditions included rotational speeds of 500 r/min and 150 r/min for the driving and following samples, respectively, resulting in a slip ratio of 70% and a sliding speed of 1.04 m/s (based on a diameter of ϕ57 mm). The tests were performed under sufficient lubrication with VG40 industrial oil, supplied at a flow rate of 0.5 L/min and a temperature of 40 ℃. A sudden increase in the friction coefficient was used as the criterion for scuffing failure. The scuffing load capacity and failure behavior of the different cladded samples were compared with those of uncladded carburized samples. The microstructure of the laser-cladded coating and the effect of the cladding process on different substrate materials were analyzed through scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), a Vickers hardness tester, and a metallographic microscope before and after the scuffing tests. The results showed that the laser-cladded coating mainly consisted of dendritic structures, cellular crystals, and irregular particles. It had a thickness of approximately 1.2 mm and a hardness between 690HV0.1 and 730HV0.1, which was comparable to that of a carburized tooth surface. During the cladding process, the tempered steel near the cladded coating underwent a secondary quenching process, forming lath martensite and lower bainite, while the lower part of the heat-affected zone experienced tempering, resulting in spheroidized structures. For the carburized steel, its heat-affected zone showed coarse, needle-like martensite at the top, refined structures in the middle, and troostite at the bottom, with an overall tempering and softening trend. Compared to the uncladded samples, the resistance to scuffing increased by 94.4% for the cladded tempered samples, 61.3% for the cladded carburized samples, and 50.7% for the repaired samples. This significant improvement was primarily attributed to the self-lubricating effect of the laser-cladded layer. Analysis of the failure mechanism indicated that the cladded coating significantly increased the critical failure load by altering the path of crack initiation and propagation. However, for the repaired samples, the entire cladded coating was prone to spalling off due to weaker interfacial bonding. This study provides both experimental evidence and theoretical support for gear surface strengthening and repair.
关键词
激光熔覆 /
自润滑涂层 /
齿轮胶合 /
齿轮钢 /
微观组织 /
表面修复
Key words
laser cladding /
self-lubricating coating /
scuffing /
gear steel /
microstructure /
surface repair
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基金
国家重点研发计划（2024YFB3410302）
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