基于有限元仿真的激光冲击调控镍基高温合金熔覆层残余应力研究

盛湘飞; 苟江龙; 朱明晋; 邹翔; 李智

doi:10.16490/j.cnki.issn.1001-3660.2026.14.009

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表面技术 ›› 2026, Vol. 55 ›› Issue (14) : 102-114. DOI: 10.16490/j.cnki.issn.1001-3660.2026.14.009

激光表面改性技术

基于有限元仿真的激光冲击调控镍基高温合金熔覆层残余应力研究

盛湘飞^a,*, 苟江龙^a, 朱明晋^a, 邹翔^a, 李智^b

作者信息 +

Regulation of Residual Stress in the Nickel-based Superalloy Cladding Layer by Laser Shock Based on Finite Element Simulation

SHENG Xiangfei^a,*, GOU Jianglong^a, ZHU Mingjin^a, ZOU Xiang^a, LI Zhi^b

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文章历史 +

摘要

目的揭示激光冲击诱导应力波调控镍基高温合金熔覆层残余应力的作用机制及变化规律。方法基于热-力顺序耦合等方法建立激光熔覆（LC）与激光冲击强化（LSP）复合工艺有限元模型,并采用表面平均残余应力（σ_avg）、残余应力波动幅值（Δσ）及残余压应力深度（h_avg）对熔覆层残余应力分布特征进行表征。结果在本文工艺条件下,熔覆层残余应力以拉伸应力为主,最大为809 MPa。经LSP处理后,熔覆层应力出现释放与重构,表面及次表面均形成了压缩应力。此外,增加峰值压力P_max（由2.6 GPa至4.4 GPa）、脉宽τ（由6 ns 至22 ns）和搭接率β（由0%至80%）,均可获得较高水平的σ_avg（分别由274 MPa 转变至-455 MPa、198 MPa 转变至-397 MPa、21.5 MPa 转变至-204 MPa）和较大的h_avg（分别由0 mm 增至0.4 mm、0 mm 增至0.47 mm、0.03 mm 增至0.4 mm）;表面残余应力均匀性则随P_max的增加而降低（Δσ由61 MPa增至188 MPa）,随τ的增加出现先降低后波动振荡的变化趋势（Δσ由59 MPa增加至249 MPa）,随β的增加而增加（Δσ由440 MPa降低至27 MPa）。结论 LC过程会产生高幅值的拉应力,而LSP通过诱发表层材料发生高应变率梯度塑性变形,形成稳定有益的压缩残余应力场。通过合理优化LSP工艺参数可实现较高幅值、具有一定深度且分布均匀的压缩残余应力层。

Abstract

The work aims to establish a finite element simulation model for the combined process of laser cladding (LC) and laser shock peening (LSP). The element birth-death technique was employed to simulate the progressive material deposition, and a thermal-mechanical sequential coupling approach combined with explicit-implicit dynamic analysis was adopted to carry out the simulation. To systematically characterize the residual stress distribution in the cladding layer, three key evaluation parameters were introduced: the surface average residual stress (σ_avg), which reflected the mean stress level over the treated area, the residual stress fluctuation amplitude (Δσ), which quantified the spatial non-uniformity of the stress field and the compressive residual stress depth (h_avg), which measured the effective penetration of the beneficial compressive stresses. On this basis, the interaction mechanism and evolution behavior of residual stress in a laser-cladded nickel-based superalloy layer subjected to laser shock-induced stress waves were investigated, with particular emphasis on the effect of different LSP processing parameters. The results were as follows: 1) Under the given process conditions, the residual stress in the cladding layer was predominantly tensile stress with a maximum value of 809 MPa, indicating that the material experienced significant constraint during the cooling-induced shrinkage process. After LSP treatment, the original tensile stress was effectively relieved and redistributed, resulting in the formation of a stable compressive residual stress field in both the surface and subsurface regions of the cladding layer, which significantly improved the overall stress state. 2) Further analysis revealed that higher σ_avg (changing from 274 MPa to -455 MPa, 198 MPa to -397 MPa and 21.5 MPa to -204 MPa, respectively) and larger h_avg (increasing from 0 mm to 0.4 mm, 0 mm to 0.47 mm and 0.03 mm to 0.4 mm) could be obtained by increasing the peak pressure P_max (from 2.6 GPa to 4.4 GPa), pulse duration τ (from 6 ns to 22 ns) and overlap ratio β (from 0% to 80%). However, the uniformity of the residual stress distribution exhibited a complex dependence on the processing parameters. With the increasing P_max, Δσ increased from 61 MPa to 188 MPa, indicating intensified stress fluctuations. With the increasing τ, Δσ showed a fluctuating upward trend from 59 MPa to 249 MPa, suggesting a non-linear response. In contrast, Δσ decreased significantly from 440 MPa to 27 MPa with the increasing β, indicating that a higher overlap ratio contributed to improving the uniformity of the residual stress distribution. The analysis indicated that, during the laser cladding process, the temperature field within the material was markedly non-uniform. The expansion of high-temperature regions during heating was constrained by adjacent low-temperature regions or external boundaries, which led to the development of tensile stress in these regions during cooling. In contrast, LSP induced ultra-high strain rate plastic deformation with a gradient distribution in the surface layer of the cladding, thereby generating a stable and beneficial compressive residual stress field. Furthermore, by optimizing the LSP processing parameters, a compressive residual stress field with higher magnitude, improved uniformity, and greater penetration depth could be achieved. These improvements significantly enhance the mechanical properties and service reliability of the cladding layer, providing important theoretical support and practical guidance for optimizing composite surface strengthening processes.

导出引用

盛湘飞, 苟江龙, 朱明晋, 邹翔, 李智. 基于有限元仿真的激光冲击调控镍基高温合金熔覆层残余应力研究[J]. 表面技术. 2026, 55(14): 102-114

SHENG Xiangfei, GOU Jianglong, ZHU Mingjin, ZOU Xiang, LI Zhi. Regulation of Residual Stress in the Nickel-based Superalloy Cladding Layer by Laser Shock Based on Finite Element Simulation[J]. Surface Technology. 2026, 55(14): 102-114

中图分类号： TG178

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