Single-track geometrical characteristics under different energy input and mass addition in coaxial laser cladding

doi:10.1007/s40436-023-00478-6

Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (4): 742-763.doi: 10.1007/s40436-023-00478-6

Single-track geometrical characteristics under different energy input and mass addition in coaxial laser cladding

Yan-Hua Bian^1,3,4, Chong-Xin Tian^1,3, Bo Chen^1,3, Bin-Xin Dong^1,3, Shao-Xia Li^1,3, Zhi-Yong Li^1,3, Yang-Rui Nan⁴, Xiu-Li He^1,2,3, Gang Yu^1,2,3

1. Institute of Mechanics, Chinese Academy of Sciences, Beijing, 100190, People's Republic of China;
2. Center of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing, 100049, People's Republic of China;
3. School of Engineering Science, University of Chinese Academy of Sciences, Beijing, 100049, People's Republic of China;
4. Research Institute of 3D printing, Beijing City University, Beijing, 100083, People's Republic of China

收稿日期:2023-03-11 修回日期:2023-05-11 发布日期:2024-12-06
通讯作者: Xiu-Li He,E-mail:xlhe@imech.ac.cn;Gang Yu,E-mail:gyu@imech.ac.cn E-mail:xlhe@imech.ac.cn;gyu@imech.ac.cn
作者简介:Yan-Hua Bian is a Ph.D. candidate at the Institute of Mechanics, Chinese Academy of Sciences, China. Her research interests include additive manufacturing, fused deposition modelling, and selective laser melting. Chong-Xin Tian is an assistant professor at the Institute of Mechanics at the Chinese Academy of Sciences, China. His research interests include additive manufacturing and the surface nanocrystallization of materials. Bo Chen is a Ph.D. candidate at the Institute of Mechanics, Chinese Academy of Sciences, China. His research interests include direct energy deposition and related computational material processing. Bin-Xin Dong is a Ph.D. candidate at the Institute of Mechanics, Chinese Academy of Sciences, China. His research interests include laser cladding, welding and joining. Shao-Xia Li is an associate professor at the Institute of Mechanics of the Chinese Academy of Sciences in China. She holds a Ph.D. degree from the Institute of Mechanics, Chinese Academy of Sciences, China. Her research interests include additive manufacturing and laser surface modifications. Zhi-Yong Li is an assistant professor at the Institute of Mechanics at the Chinese Academy of Sciences in China. His research interests include additive manufacturing, welding and joining. Yang-Rui Nan is a research assistant at Beijing City University, China. His research interests include power-bed-fusion additive manufacturing. Xiu-Li He is an associate professor at the Institute of Mechanics of the Chinese Academy of Sciences in China. She received her Ph.D. from Pennsylvania State University, United States. She is engaged in the research of additive manufacturing, welding, joining, and computational material processing research. Gang Yu is a professor at the Institute of Mechanics at the Chinese Academy of Sciences. He received his Ph.D. from Heriot-Watt University in the United Kingdom. His research focuses on advanced laser and additive manufacturing technologies.
基金资助:
This work was supported by the National Natural Science Foundation of China (Grant Nos. 11502269 and 11672304) and the Beijing Municipal Commission of Science and Technology (Grant No. Z181100003818015).

Single-track geometrical characteristics under different energy input and mass addition in coaxial laser cladding

Yan-Hua Bian^1,3,4, Chong-Xin Tian^1,3, Bo Chen^1,3, Bin-Xin Dong^1,3, Shao-Xia Li^1,3, Zhi-Yong Li^1,3, Yang-Rui Nan⁴, Xiu-Li He^1,2,3, Gang Yu^1,2,3

1. Institute of Mechanics, Chinese Academy of Sciences, Beijing, 100190, People's Republic of China;
2. Center of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing, 100049, People's Republic of China;
3. School of Engineering Science, University of Chinese Academy of Sciences, Beijing, 100049, People's Republic of China;
4. Research Institute of 3D printing, Beijing City University, Beijing, 100083, People's Republic of China

Received:2023-03-11 Revised:2023-05-11 Published:2024-12-06
Contact: Xiu-Li He,E-mail:xlhe@imech.ac.cn;Gang Yu,E-mail:gyu@imech.ac.cn E-mail:xlhe@imech.ac.cn;gyu@imech.ac.cn
Supported by:
This work was supported by the National Natural Science Foundation of China (Grant Nos. 11502269 and 11672304) and the Beijing Municipal Commission of Science and Technology (Grant No. Z181100003818015).

摘要/Abstract

摘要： To provide a broad processing window with a high deposition rate, a comprehensive analysis of single-track geometrical characteristics over a wide range of laser energies and mass inputs in laser cladding is necessary. The formation of a single cladding track of Inconel 718 on a substrate by coaxial laser cladding, with a wide range of laser power from 1 200 W to 3 900 W and a powder feeding rate from 5 g/min to 35 g/min, was studied from both theoretical and experimental points of view. A quantitative model of powder concentration distribution was developed based on the powder transport morphology obtained by high-speed photography. Linear regression models were established between nine geometrical characteristics and the combined process parameters of laser power and powder feeding rate, written as P^αF^β, to quantitatively analyze the geometrical characteristics of the clad. These were confirmed by large correlation coefficients and analysis of residuals. From the findings we deduced that more energy input enhanced the outward direction of Marangoni convection, leading to the melt pool undergoing evolution from shallow dilution and flat dilution to fluctuating dilution. An almost linear relationship was found between the cladding width, W, and the laser power, indicating that laser energy accumulation was a major factor in the evolution of W. The increase ratio of the cladding height, h_c, ranged from 640% to 360% along with an increase in the powder feeding rate, implying that the evolution of h_c, was dominated by the powder feeding rate. The total area of the cross-section, A; the area of the clad, A_c; the area of the molten substrate, A_m; the total height of the cross-section, H; the penetration depth, h_m; the dilution ratio, D; and the wetting angle, θ, were determined by a complex coupling of energy input and mass accumulation, and they are proportional to P^0.5F^0.2, P^0.2F^0.5, P^0.5/F^0.2, P^0.3F, P^0.5/F^0.2, P^0.2/F^0.2, and P^0.2/F^0.2, respectively. This research aims to provide general knowledge on the influence of energy input and mass addition on the geometrical characteristics of the clad and its related influence mechanism. Such information could provide a reference and basis for promoting the practical application of laser cladding technology.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00478-6

关键词: Laser cladding, Inconel 718, Clad geometry, Linear regression analysis, Powder concentration

Abstract: To provide a broad processing window with a high deposition rate, a comprehensive analysis of single-track geometrical characteristics over a wide range of laser energies and mass inputs in laser cladding is necessary. The formation of a single cladding track of Inconel 718 on a substrate by coaxial laser cladding, with a wide range of laser power from 1 200 W to 3 900 W and a powder feeding rate from 5 g/min to 35 g/min, was studied from both theoretical and experimental points of view. A quantitative model of powder concentration distribution was developed based on the powder transport morphology obtained by high-speed photography. Linear regression models were established between nine geometrical characteristics and the combined process parameters of laser power and powder feeding rate, written as P^αF^β, to quantitatively analyze the geometrical characteristics of the clad. These were confirmed by large correlation coefficients and analysis of residuals. From the findings we deduced that more energy input enhanced the outward direction of Marangoni convection, leading to the melt pool undergoing evolution from shallow dilution and flat dilution to fluctuating dilution. An almost linear relationship was found between the cladding width, W, and the laser power, indicating that laser energy accumulation was a major factor in the evolution of W. The increase ratio of the cladding height, h_c, ranged from 640% to 360% along with an increase in the powder feeding rate, implying that the evolution of h_c, was dominated by the powder feeding rate. The total area of the cross-section, A; the area of the clad, A_c; the area of the molten substrate, A_m; the total height of the cross-section, H; the penetration depth, h_m; the dilution ratio, D; and the wetting angle, θ, were determined by a complex coupling of energy input and mass accumulation, and they are proportional to P^0.5F^0.2, P^0.2F^0.5, P^0.5/F^0.2, P^0.3F, P^0.5/F^0.2, P^0.2/F^0.2, and P^0.2/F^0.2, respectively. This research aims to provide general knowledge on the influence of energy input and mass addition on the geometrical characteristics of the clad and its related influence mechanism. Such information could provide a reference and basis for promoting the practical application of laser cladding technology.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00478-6

Key words: Laser cladding, Inconel 718, Clad geometry, Linear regression analysis, Powder concentration

Yan-Hua Bian, Chong-Xin Tian, Bo Chen, Bin-Xin Dong, Shao-Xia Li, Zhi-Yong Li, Yang-Rui Nan, Xiu-Li He, Gang Yu. Single-track geometrical characteristics under different energy input and mass addition in coaxial laser cladding[J]. Advances in Manufacturing, 2024, 12(4): 742-763.

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Single-track geometrical characteristics under different energy input and mass addition in coaxial laser cladding

Single-track geometrical characteristics under different energy input and mass addition in coaxial laser cladding

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