Industrial applications of laser cladding

Author(s):  
Thierry Marchione
Coatings ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 356 ◽  
Author(s):  
Guofu Lian ◽  
Hao Zhang ◽  
Yang Zhang ◽  
Martin L. Tanaka ◽  
Changrong Chen ◽  
...  

Multi-track laser cladding is the primary technology used in industrial applications for surface reinforcement and remanufacturing of broken parts. In this study, the influence of processing parameters on multi-track laser cladding was investigated using a Taguchi orthogonal experimental design. A multi-response grey relational analysis (GRA) was employed to identify laser cladding processing parameters that simultaneously optimize the flatness ratio of the coating and the cladding efficiency. The optimal parameters setting found by GRA were validated experimentally. Results showed that the flatness ratio and cladding efficiency were closely correlated to the overlap rate and laser power, where the overlap rate shows the most significant impact on the flatness ratio and the laser power shows the most significant impact on cladding efficiency. Results from the validation experiment were within one percent (0.97% error) of the predicted value. This demonstrates the benefits of utilizing GRA in laser cladding process optimization. The methods presented in this paper can be used to identify ideal processing parameters for multi-response multi-track laser cladding processes or other industrial applications.


Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 2745
Author(s):  
Paweł Kołodziejczak ◽  
Dariusz Golański ◽  
Tomasz Chmielewski ◽  
Marcin Chmielewski

The addition of Rhenium up to 6% to Ni-Cr alloys can dramatically improve the corrosion and oxide resistance of deposited coatings at high operating temperatures. Ni-Cr+Re layers can be successfully produced using conventional powder metallurgy, high rate solidification (HRS), or magnetron sputtering methods. However, in industrial applications, high-performance deposition methods are needed, e.g., laser cladding. Laser cladding has several advantages, e.g., metallurgical bonding, narrow heat-affected zone (HAZ), low dilution, and slight thermal damage to the substrate. In this paper, a powder Ni-Cr composite with 1% (wt.) of Rhenium was produced, then deposited onto a steel substrate (16Mo3) by laser cladding to assess the micro and macrostructural properties of the obtained layers. Besides the macro and microscopic observations, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) microanalysis of the deposit and HAZ as well as microhardness measurements have been conducted. The microstructure observations revealed four subareas of HAZ gradually changing from the fusion line towards the base material. Maximum hardness occurred in the HAZ, mainly in areas closer to the clad/substrate interface, reaching up to 350–400 HV. No sudden changes in the composition of the deposit and the area of fusion line were observed.


2003 ◽  
Author(s):  
Rafal Jendrzejewski ◽  
Gerard Sliwinski ◽  
Ana Conde ◽  
Juan J. de Damborenea

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 947 ◽  
Author(s):  
Guofu Lian ◽  
Yang Zhang ◽  
Hao Zhang ◽  
Xu Huang ◽  
Changrong Chen ◽  
...  

Laser cladding on curved surfaces is essential in industrial applications for restoration and remanufacturing of high-value parts. This study investigated the influence of different factors on clad width, clad height, and dilution rate in curved surface laser cladding with curved path. Mathematical models were developed using central composite designs to predict these geometric characteristics by controlling laser power, scanning speed, gas flow, and altering the outside radius of the cylindrical substrate. Analysis of variance and response surface methodology indicated that clad width increased with increasing laser power and reducing scanning speed. Clad height positively correlated to laser power and negatively correlated to the outside radius of the cylindrical substrate. Increasing the laser power while decreasing the scanning speed led to an increase in dilution rate. Afterwards, the geometric characteristics of the clad were improved by optimizing these factors with the target to maximize clad width and height as well as to minimize dilution rate. The difference between model predictions and experimental validations for clad width, clad height, and dilution rate were 3.485%, 3.863%, and 6.566%, respectively. The predicted accuracy was verified with these models, and they were able to provide theoretical guidance to predict and control the geometric characteristics of curved surface laser cladding with a curved path.


Author(s):  
U. S. Starikova ◽  
◽  
N. N. Soboleva ◽  
A. V. Makarov ◽  
E. V. Kharanzhevsky ◽  
...  

Laser cladding is increasingly frequently used in various branches of mechanical engineering since it has such advantages over traditional methods of depositing coatings as high heating and cooling rates and minimal mixing of base and melting materials. Laser-clad coatings are usually characterized by a fine-grained structure and a minimal heat-affected zone. Coatings formed from the Ni–Cr–B–Si powders are also very common in industrial applications, as they have good resistance to wear, corrosion, erosion, etc. Various strengthening particles can be added to this group of powders to improve the properties of the deposited coating. Boron carbides can act as such particles since they have high hardness, thermodynamic stability, and wear resistance. In this regard, the paper investigated the influence of the 7 wt. % of boron carbide B4C addition on the structure and hardness of the NiCrBSi coating formed by laser cladding of PG-SR2 powder on the surface of 30HRA steel. Using the scanning electron microscope, the authors carried out microscopic studies of the structure of NiCrBSi and NiCrBSi–B4C coatings and presented the results of X-ray spectral microanalysis. The study shows that the structures of both coatings in the deposited state are characterized by uniformity and fine-grain structure. The investigation revealed that the samples with NiCrBSi and NiCrBSi–B4C coatings have a narrow transition zone from the deposit to the base metal. The paper presents the results of measuring the microhardness of coatings indicating a decrease in the microhardness of laser-clad nickel-based coatings with the boron carbide addition.


2019 ◽  
Vol 19 ◽  
pp. 1059-1065 ◽  
Author(s):  
Alexandru Pascu ◽  
Julia Mirza Rosca ◽  
Elena Manuela Stanciu

Author(s):  
C. F. Oster

Although ultra-thin sectioning techniques are widely used in the biological sciences, their applications are somewhat less popular but very useful in industrial applications. This presentation will review several specific applications where ultra-thin sectioning techniques have proven invaluable.The preparation of samples for sectioning usually involves embedding in an epoxy resin. Araldite 6005 Resin and Hardener are mixed so that the hardness of the embedding medium matches that of the sample to reduce any distortion of the sample during the sectioning process. No dehydration series are needed to prepare our usual samples for embedding, but some types require hardening and staining steps. The embedded samples are sectioned with either a prototype of a Porter-Blum Microtome or an LKB Ultrotome III. Both instruments are equipped with diamond knives.In the study of photographic film, the distribution of the developed silver particles through the layer is important to the image tone and/or scattering power. Also, the morphology of the developed silver is an important factor, and cross sections will show this structure.


Author(s):  
W.M. Stobbs

I do not have access to the abstracts of the first meeting of EMSA but at this, the 50th Anniversary meeting of the Electron Microscopy Society of America, I have an excuse to consider the historical origins of the approaches we take to the use of electron microscopy for the characterisation of materials. I have myself been actively involved in the use of TEM for the characterisation of heterogeneities for little more than half of that period. My own view is that it was between the 3rd International Meeting at London, and the 1956 Stockholm meeting, the first of the European series , that the foundations of the approaches we now take to the characterisation of a material using the TEM were laid down. (This was 10 years before I took dynamical theory to be etched in stone.) It was at the 1956 meeting that Menter showed lattice resolution images of sodium faujasite and Hirsch, Home and Whelan showed images of dislocations in the XlVth session on “metallography and other industrial applications”. I have always incidentally been delighted by the way the latter authors misinterpreted astonishingly clear thickness fringes in a beaten (”) foil of Al as being contrast due to “large strains”, an error which they corrected with admirable rapidity as the theory developed. At the London meeting the research described covered a broad range of approaches, including many that are only now being rediscovered as worth further effort: however such is the power of “the image” to persuade that the above two papers set trends which influence, perhaps too strongly, the approaches we take now. Menter was clear that the way the planes in his image tended to be curved was associated with the imaging conditions rather than with lattice strains, and yet it now seems to be common practice to assume that the dots in an “atomic resolution image” can faithfully represent the variations in atomic spacing at a localised defect. Even when the more reasonable approach is taken of matching the image details with a computed simulation for an assumed model, the non-uniqueness of the interpreted fit seems to be rather rarely appreciated. Hirsch et al., on the other hand, made a point of using their images to get numerical data on characteristics of the specimen they examined, such as its dislocation density, which would not be expected to be influenced by uncertainties in the contrast. Nonetheless the trends were set with microscope manufacturers producing higher and higher resolution microscopes, while the blind faith of the users in the image produced as being a near directly interpretable representation of reality seems to have increased rather than been generally questioned. But if we want to test structural models we need numbers and it is the analogue to digital conversion of the information in the image which is required.


Author(s):  
C J R Sheppard

The confocal microscope is now widely used in both biomedical and industrial applications for imaging, in three dimensions, objects with appreciable depth. There are now a range of different microscopes on the market, which have adopted a variety of different designs. The aim of this paper is to explore the effects on imaging performance of design parameters including the method of scanning, the type of detector, and the size and shape of the confocal aperture.It is becoming apparent that there is no such thing as an ideal confocal microscope: all systems have limitations and the best compromise depends on what the microscope is used for and how it is used. The most important compromise at present is between image quality and speed of scanning, which is particularly apparent when imaging with very weak signals. If great speed is not of importance, then the fundamental limitation for fluorescence imaging is the detection of sufficient numbers of photons before the fluorochrome bleaches.


Author(s):  
R. T. Chen ◽  
R.A. Norwood

Sol-gel processing has been used to control the structure of a material on a nanometer scale in preparing advanced ceramics and glasses. Film coating using the sol-gel process was also found to be a viable process technology in applications such as optical, porous, antireflection and hard coatings. In this study, organically modified silicate (Ormosil) coatings are applied to PET films for various industrial applications. Sol-gel materials are known to exhibit nanometer scale structures which havepreviously been characterized by small-angle X-ray scattering (SAXS), neutron scattering and light scattering. Imaging of the ultrafine sol-gel structures has also been performed using an ultrahigh resolution replica/TEM technique. The objective of this study was to evaluate the ultrafine structures inthe sol gel coatings using a direct imaging technique: atomic force microscopy (AFM). In addition, correlation of microstructures with processing parameters, coating density and other physical properties will be discussed.The materials evaluated are organically modified silicate coatings on PET film substrates. Refractive index measurement by the prism coupling method was used to assess density of the sol-gel coating.AFM imaging was performed on a Nanoscope III AFM (by Digital Instruments) using constant force mode. Solgel coating samples coated with a thin layer of Ft (by ion beam sputtering) were also examined by STM in order to confirm the structures observed in the contact type AFM. In addition, to compare the previous results, sol-gel powder samples were also prepared by ultrasonication followed by Pt/Au shadowing and examined using a JEOL 100CX TEM.


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