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 (σavg), 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 (havg), 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 σavg (changing from 274 MPa to -455 MPa, 198 MPa to -397 MPa and 21.5 MPa to -204 MPa, respectively) and larger havg (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 Pmax (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 Pmax, 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.
Key words
laser shock peening /
nickel-based superalloy /
laser cladding /
residual stress /
stress wave /
finite element simulation
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Funding
National Natural Science Foundation Project (51575117); The Hunan Natural Science Foundation Project (2019JJ50519)
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