Optimization for furnace-assisted laser cladding process parameter of crack-free ceramic-based coating by response surface methodology

IF 5.1 2区材料科学 Q1 MATERIALS SCIENCE, CERAMICS

Ceramics International Pub Date : 2025-04-01 DOI:10.1016/j.ceramint.2025.01.027

Zhao Yong , Yunfei Wang , Gaolin Yang , Yuelin Shi , QunLi Zhang , Jianhua Yao

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引用次数: 0

Abstract

Ceramic-based coating, recognized as advanced surface treatment material, which is widely utilized across various sectors including aerospace, automotive, and industrial manufacturing. This extensive application is attributed to their remarkable properties such as wear resistance, high-temperature tolerance, and corrosion resistance. However, ceramic phase of the coating experienced excessive residual stress due to rapid cooling and heating effects, during the laser cladding process. Thus, the formation of cracks and pores in the coating is a common issue, posing significant challenge to the preparation of ceramic-based coating. This study employed the response surface methodology to optimize the process parameters of furnace-assisted laser cladding for fabricating 60WC coating on 45# steel substrate. The effects of laser power, scanning rate, powder feeding rate, and preheating temperature on coating height, dilution rate and micro-hardness were investigated comprehensively in order to achieve a crack-free 60WC coating. The results indicate that the synergistic effect of laser scanning speed and preheating temperature is of the utmost significance for attaining crack-free coatings with high hardness. Through the adjustment of these two parameters, a coating featuring high hardness and no cracks can be acquired. And it was determined by RSM that the optimal coating quality was achieved under the following conditions: 2586.13 W laser power, 740.74 mm/min laser scanning speed, 400 °C preheating temperature, and 22.0 g/min powder feeding speed, with no discernible macroscopic or microscopic cracks present.

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响应面法优化无裂纹陶瓷基涂层炉助激光熔覆工艺参数

陶瓷基涂料被公认为先进的表面处理材料，广泛应用于航空航天、汽车、工业制造等各个领域。这种广泛的应用归功于其卓越的性能，如耐磨性、耐高温性和耐腐蚀性。然而，在激光熔覆过程中，由于快速的冷却和加热作用，涂层的陶瓷相产生了过大的残余应力。因此，涂层中裂纹和孔隙的形成是一个普遍的问题，对陶瓷基涂层的制备提出了重大的挑战。采用响应面法优化了45#钢基体上激光熔覆制备60WC涂层的工艺参数。为了获得无裂纹的60WC涂层，综合研究了激光功率、扫描速率、给粉速度和预热温度对涂层高度、稀释率和显微硬度的影响。结果表明，激光扫描速度和预热温度的协同作用对获得高硬度无裂纹涂层至关重要。通过调整这两个参数，可以获得硬度高、无裂纹的涂层。RSM实验结果表明，在激光功率2586.13 W、激光扫描速度740.74 mm/min、预热温度400℃、给粉速度22.0 g/min的条件下，涂层质量最佳，且无明显的宏观和微观裂纹。

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来源期刊

Ceramics International 工程技术-材料科学：硅酸盐

CiteScore

9.40

自引率

15.40%

发文量

4558

审稿时长

25 days

期刊介绍： Ceramics International covers the science of advanced ceramic materials. The journal encourages contributions that demonstrate how an understanding of the basic chemical and physical phenomena may direct materials design and stimulate ideas for new or improved processing techniques, in order to obtain materials with desired structural features and properties. Ceramics International covers oxide and non-oxide ceramics, functional glasses, glass ceramics, amorphous inorganic non-metallic materials (and their combinations with metal and organic materials), in the form of particulates, dense or porous bodies, thin/thick films and laminated, graded and composite structures. Process related topics such as ceramic-ceramic joints or joining ceramics with dissimilar materials, as well as surface finishing and conditioning are also covered. Besides traditional processing techniques, manufacturing routes of interest include innovative procedures benefiting from externally applied stresses, electromagnetic fields and energetic beams, as well as top-down and self-assembly nanotechnology approaches. In addition, the journal welcomes submissions on bio-inspired and bio-enabled materials designs, experimentally validated multi scale modelling and simulation for materials design, and the use of the most advanced chemical and physical characterization techniques of structure, properties and behaviour. Technologically relevant low-dimensional systems are a particular focus of Ceramics International. These include 0, 1 and 2-D nanomaterials (also covering CNTs, graphene and related materials, and diamond-like carbons), their nanocomposites, as well as nano-hybrids and hierarchical multifunctional nanostructures that might integrate molecular, biological and electronic components.