激光—感应复合熔覆金属陶瓷层技术的研究
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摘要
激光熔覆金属陶瓷层具有高硬度、耐磨损与耐腐蚀等性能,在关键零部件的表面强化与修复领域具有广阔的应用前景。但是,熔覆效率低,复合层易产生气孔与裂纹等缺陷,严重阻碍了激光熔覆金属陶瓷层技术的工业化应用进程。为了提高熔覆效率与降低冶金缺陷,本文提出了激光—感应复合熔覆的新方法,对激光—感应复合熔覆金属陶瓷层技术的工艺特点、WC颗粒的烧损机理与复合层的耐磨性能等进行了研究,得到的主要结果如下:
构建了一个由CO_2激光器、高频感应加热器、自动送粉器、CNC控制台等组成的激光—感应复合熔覆平台。对激光—感应复合熔覆金属陶瓷层的工艺进行了系统研究。结果表明:最小激光比能、最大熔覆层厚度、接触角均与最大粉末面密度呈线性关系;随着感应预热温度的增加,最大熔覆效率增加;与单纯激光熔覆技术相比,激光—感应复合熔覆金属陶瓷层技术的效率可以提高约1～4倍。
系统研究了影响激光—感应复合熔覆金属陶瓷层质量的工艺参数。结果表明:与垂直光斑相比,采用平行光斑进行激光—感应复合熔覆时,可以获得较大的激光加工参数选择范围与较高的熔覆效率;通过激光高速扫描与增加送粉量,可以降低复合层的稀释率,改善WC颗粒在复合层内的均匀分布,从而获得WC含量达35%wt、高硬度且与基材呈冶金结合的无裂纹金属陶瓷层。
对激光—感应复合熔覆Ni基WC复合层内WC颗粒的烧损规律进行了详细研究。研究证实可以采用WC颗粒烧损程度的半定量公式,计算激光高速扫描时,WC颗粒在多道搭接激光—感应复合熔覆Ni基WC复合层内的烧损率,表明该公式具有较广的应用范围与较强的实用性,不仅可以应用于单纯激光熔覆金属陶瓷层时陶瓷相的烧损程度的评价,而且可以为合理评价激光—感应复合熔覆金属陶瓷层的组织与性能提供重要的理论依据。
在大量研究工作的基础上,提出了激光—感应复合熔覆铸造碳化钨—镍基合金金属陶瓷层中,粒度小于38μm的铸造WC颗粒的烧损机理,其可能的方式如下:
(1)典型的溶解扩散式烧损:WC颗粒的边缘不断受到高温Ni基合金液的浸蚀,相互交换原子,导致WC颗粒直接溶解于Ni基合金液中,并在随后的冷却过程中以M_6C和M_(12)C等碳化物形式析出;同时,Ni、Cr与Fe等原子向WC颗粒内部扩散,在WC颗粒的边缘形成一个有限厚度的合金化反应层。
(2)WC颗粒的溃散—溶解扩散复合烧损方式:部分粒径较小的WC颗粒,在激光束的直接照射下被破碎成粒径更小的碎块状WC颗粒,然后发生前已述及的典型的溶解扩散式烧损。然而,由于破碎的WC颗粒体积小,它们与Ni基合金液交互作用,可能使碎块状WC颗粒完全合金化,成为高钨含量的合金碳化物。
(3)较大尺寸的WC颗粒溃散成粒径极小的碎块状WC颗粒后,因为与高温Ni基合金液的交互作用而完全溶解于其中,并在随后的冷却过程中,以不同成分(M_6C、M_(12)C、M_(23)C_6与M_7C_3)与不同形式(块状、杆状与鱼骨状等)的合金碳化物析出。另外,原来粒度就很小的WC颗粒也可能采取这种完全溶解的烧损方式。
在激光—感应复合熔覆过程中,粘结金属的成分对WC颗粒的烧损程度影响很大。研究结果表明,当采用的粘结金属为铁基合金时,激光—感应复合熔覆Fe基WC复合层内的WC颗粒几乎完全溶解,复合层由M_6C、M_(23)C_6、马氏体与残余奥氏体等组成,其粘结金属的显微硬度低于相同工艺条件下Ni基WC复合层内粘结金属的显微硬度。这种显著差异的结果此前国内外未见类似报道。这种显著差异是由高温状态下WC颗粒在粘结金属中的溶解度、粘结金属的熔点、WC颗粒的溶解速率与粘结金属释放的潜热等因素共同决定的。这一结果对合理选择粘结金属类型具有一定的指导意义。
系统研究了激光—感应复合熔覆Ni基WC复合层、Fe基WC复合层的干滑动摩擦磨损性能,并对其磨损失效机理进行了分析。结果表明,在干滑动磨损过程中,存在粘着磨损、磨粒磨损、疲劳磨损与氧化磨损等多种磨损特征,磨屑呈片状且以剥层的方式脱落。碳化钨颗粒的含量、烧损程度对耐磨性影响很大。通过提高激光扫描速度,可以使激光—感应复合熔覆Ni基WC复合层的耐磨性提高到单纯激光熔覆同样成分Ni基WC复合层的1.4倍。主要原因是激光扫描速度增加,可以降低WC颗粒的烧损程度,提高粘结金属的硬度,改善WC颗粒的分布均匀性及其平均间距,限制粘结金属的塑性变形。
总而言之,上述结果表明,激光—感应复合熔覆金属陶瓷层具有单纯激光熔覆同样成分的金属陶瓷层更好的性能。因此,激光—感应复合熔覆金属陶瓷层技术具有广阔的工业应用前景。
Laser cladding ceramic-metal composite coating (LCCC) has high hardness, excellent wear resistance and corrosion resistance, and thus has a wide application ranges in the surface strengthening and repairing of the key components. However, the low cladding efficiency, high volume of porosities and cracks in LCCC has restricted its applications in many fields. In order to enhance the cladding efficiency and reduce the metallurgical defects, induction heating, another heat source is introduced into the laser cladding process, which is named as laser-induction hybrid cladding (LIHC) in the dissertation. The processing characteristics, the heat damage mechanisms of WC particles and the wear resistance of the composite coating by LIHC were studied systemically. The main results were as following.
A system of LIHC was developed, which was composed of a CO_2 laser, a high frequency induction heater, an auto-feeding powder apparatus and CNC controller, etc, based on which the processing parameters of the ceramic-metal composite coatings produced by LIHC were investigated. The results showed that the minimum laser specific energy, the maximum cladding height and the contact angle had a linear relationship with the maximum powder density per area. The maximum cladding efficiency increased with the increasing of the preheated average temperature of the substrate by induction heating. Moreover, the efficiency of LIHC can be increased to 1-4 times higher than that of the individual laser cladding.
The effects of the laser processing parameters on the quality of the composite coatings by LIHC were investigated systemically. The results demonstrated that the choice range of laser processing parameters and the cladding efficiency using the parallel spot were wider and higher than those using the perpendicular spot during LIHC, respectively. By increasing laser scanning speed and powder feeding rate, the dilution of the composite coating by LIHC was decreased, the homogeneity of WC particles distribution was improved. As a result, the free-crack ceramic-metal composite coatings with a low dilution and high microhardness were obtained, with the weight fraction of WC particles higher than 35%wt and the metallurgical bonding between the composite coatings and the substrate.
The heat damage fashions and mechanisms of WC particle in Ni-based WC composite coatings by LIHC were studied in detail. The results proved that the formulas of half quantity on the heat damage level of WC particles introduced before can be adopted to evaluate the heat damage extent of WC particles in multi-pass overlapping Ni-based WC composite coatings if the high laser scanning speed was adopted during LIHC, which demonstrated that the formulas not only had an extensive application range and strong practicality, but also may provide an important theoretical basis to evaluate the microstructure and properties of laser-induction hybrid cladding Ni-based WC composite coatings.
When Ni-based alloy was used as the matrix alloy in ceramic-metal composite coatings by LIHC, the heat damage mechanisms of WC particles usually took the following models:
(1) The dissolution-diffusion heat damage fashion: WC particles were continually dissolved by the molten Ni-based alloy at high temperature and exchanged their atoms each other, which resulted in WC particles dissolveng directly into Ni-based alloy solution and then precipitated in the format of M_6C, M_(12)C and other carbides during the rapid solidification processing. In the meantime, the alloying elements such as Ni, Cr and Fe diffused into WC particles rapidly, thus forming an alloyed reaction layer with limited thickness.
(2) The dispersion-dissolution diffusion hybrid heat damage fashion: a part of WC particles with small size were dispersed into several small pieces of WC particles when they were irradiated by laser, which was heat damaged as the dissolution-diffusion heat damage fashion above mentioned. However, these dispersed WC particles with relatively smaller size may change into the alloyed carbides with high W concentration after they interacted with Ni-based alloy solution at high temperature.
(3) WC particles with relatively smaller size may dissolve into Ni-based alloy solution completely, and then precipitated into the composite coating in the format of carbides such as M_6C, M_(12)C, M_(23)C_6 and M_7C_3 with different morphology (i.e. blocky, bar-like and fish-bone shape).
The compositions of the matrix alloys have a big effect on the heat damage of the WC particles. It was found that WC particles had a complete dissolution in Fe-based WC composite coatings produced by LIHC. The coatings was composed of M_6C, M_(23)C_6 martensite and the retained austenite and the microhardness of the binder metal was lower than that in Ni-based WC composite coating under the same processing condtions. This result has not reported before. This difference was mainly caused by the difference of the dissolution level and rates of WC particles in the binder metal, melting point and latent heat between Ni-based and Fe-based alloy. The above results were highly helpful to choose a reasonable binder alloy.
The sliding wear resistance and mechanisms of Ni-based WC composite coatings and Fe-based composite coatings prepared by LIHC were studied systematically. The adhesion wear, abrasive wear, fatigue wear and oxidation wear were simultaneously found in the samples by dry sliding wear process of the ceramic-metal composite coatings, the debris with lamellar structure were sheared from the composite coatings by the delamination pattern. Especially, the heat damage extent of the WC particles had a big effect on the sliding wear resistance of the composite coatings. By increasing laser scanning speed, the wear resistance of Ni-based WC composite coatings by LIHC can be 1.4 times as much as that of Ni-based WC composite coatings by the laser cladding with the same composition of the alloying powders. The main reason was that increasing laser scanning speed can decrease the heat damage extent, which can increase the microhardness of the composite coatings, improve the homogeneous distribution of WC particles, decrease the average distance of WC particles and limit the plastic transformation of the binder.
In summary, the above results demonstrated that laser-induction hybrid cladding ceramic-metal composite coatings had more excellent propeties than the laser cladding ceramic-metal composite coatings with the same composition of alloy powders, which may find a wide application field in industrial area.
构建了一个由CO_2激光器、高频感应加热器、自动送粉器、CNC控制台等组成的激光—感应复合熔覆平台。对激光—感应复合熔覆金属陶瓷层的工艺进行了系统研究。结果表明:最小激光比能、最大熔覆层厚度、接触角均与最大粉末面密度呈线性关系;随着感应预热温度的增加,最大熔覆效率增加;与单纯激光熔覆技术相比,激光—感应复合熔覆金属陶瓷层技术的效率可以提高约1～4倍。
系统研究了影响激光—感应复合熔覆金属陶瓷层质量的工艺参数。结果表明:与垂直光斑相比,采用平行光斑进行激光—感应复合熔覆时,可以获得较大的激光加工参数选择范围与较高的熔覆效率;通过激光高速扫描与增加送粉量,可以降低复合层的稀释率,改善WC颗粒在复合层内的均匀分布,从而获得WC含量达35%wt、高硬度且与基材呈冶金结合的无裂纹金属陶瓷层。
对激光—感应复合熔覆Ni基WC复合层内WC颗粒的烧损规律进行了详细研究。研究证实可以采用WC颗粒烧损程度的半定量公式,计算激光高速扫描时,WC颗粒在多道搭接激光—感应复合熔覆Ni基WC复合层内的烧损率,表明该公式具有较广的应用范围与较强的实用性,不仅可以应用于单纯激光熔覆金属陶瓷层时陶瓷相的烧损程度的评价,而且可以为合理评价激光—感应复合熔覆金属陶瓷层的组织与性能提供重要的理论依据。
在大量研究工作的基础上,提出了激光—感应复合熔覆铸造碳化钨—镍基合金金属陶瓷层中,粒度小于38μm的铸造WC颗粒的烧损机理,其可能的方式如下:
(1)典型的溶解扩散式烧损:WC颗粒的边缘不断受到高温Ni基合金液的浸蚀,相互交换原子,导致WC颗粒直接溶解于Ni基合金液中,并在随后的冷却过程中以M_6C和M_(12)C等碳化物形式析出;同时,Ni、Cr与Fe等原子向WC颗粒内部扩散,在WC颗粒的边缘形成一个有限厚度的合金化反应层。
(2)WC颗粒的溃散—溶解扩散复合烧损方式:部分粒径较小的WC颗粒,在激光束的直接照射下被破碎成粒径更小的碎块状WC颗粒,然后发生前已述及的典型的溶解扩散式烧损。然而,由于破碎的WC颗粒体积小,它们与Ni基合金液交互作用,可能使碎块状WC颗粒完全合金化,成为高钨含量的合金碳化物。
(3)较大尺寸的WC颗粒溃散成粒径极小的碎块状WC颗粒后,因为与高温Ni基合金液的交互作用而完全溶解于其中,并在随后的冷却过程中,以不同成分(M_6C、M_(12)C、M_(23)C_6与M_7C_3)与不同形式(块状、杆状与鱼骨状等)的合金碳化物析出。另外,原来粒度就很小的WC颗粒也可能采取这种完全溶解的烧损方式。
在激光—感应复合熔覆过程中,粘结金属的成分对WC颗粒的烧损程度影响很大。研究结果表明,当采用的粘结金属为铁基合金时,激光—感应复合熔覆Fe基WC复合层内的WC颗粒几乎完全溶解,复合层由M_6C、M_(23)C_6、马氏体与残余奥氏体等组成,其粘结金属的显微硬度低于相同工艺条件下Ni基WC复合层内粘结金属的显微硬度。这种显著差异的结果此前国内外未见类似报道。这种显著差异是由高温状态下WC颗粒在粘结金属中的溶解度、粘结金属的熔点、WC颗粒的溶解速率与粘结金属释放的潜热等因素共同决定的。这一结果对合理选择粘结金属类型具有一定的指导意义。
系统研究了激光—感应复合熔覆Ni基WC复合层、Fe基WC复合层的干滑动摩擦磨损性能,并对其磨损失效机理进行了分析。结果表明,在干滑动磨损过程中,存在粘着磨损、磨粒磨损、疲劳磨损与氧化磨损等多种磨损特征,磨屑呈片状且以剥层的方式脱落。碳化钨颗粒的含量、烧损程度对耐磨性影响很大。通过提高激光扫描速度,可以使激光—感应复合熔覆Ni基WC复合层的耐磨性提高到单纯激光熔覆同样成分Ni基WC复合层的1.4倍。主要原因是激光扫描速度增加,可以降低WC颗粒的烧损程度,提高粘结金属的硬度,改善WC颗粒的分布均匀性及其平均间距,限制粘结金属的塑性变形。
总而言之,上述结果表明,激光—感应复合熔覆金属陶瓷层具有单纯激光熔覆同样成分的金属陶瓷层更好的性能。因此,激光—感应复合熔覆金属陶瓷层技术具有广阔的工业应用前景。
Laser cladding ceramic-metal composite coating (LCCC) has high hardness, excellent wear resistance and corrosion resistance, and thus has a wide application ranges in the surface strengthening and repairing of the key components. However, the low cladding efficiency, high volume of porosities and cracks in LCCC has restricted its applications in many fields. In order to enhance the cladding efficiency and reduce the metallurgical defects, induction heating, another heat source is introduced into the laser cladding process, which is named as laser-induction hybrid cladding (LIHC) in the dissertation. The processing characteristics, the heat damage mechanisms of WC particles and the wear resistance of the composite coating by LIHC were studied systemically. The main results were as following.
A system of LIHC was developed, which was composed of a CO_2 laser, a high frequency induction heater, an auto-feeding powder apparatus and CNC controller, etc, based on which the processing parameters of the ceramic-metal composite coatings produced by LIHC were investigated. The results showed that the minimum laser specific energy, the maximum cladding height and the contact angle had a linear relationship with the maximum powder density per area. The maximum cladding efficiency increased with the increasing of the preheated average temperature of the substrate by induction heating. Moreover, the efficiency of LIHC can be increased to 1-4 times higher than that of the individual laser cladding.
The effects of the laser processing parameters on the quality of the composite coatings by LIHC were investigated systemically. The results demonstrated that the choice range of laser processing parameters and the cladding efficiency using the parallel spot were wider and higher than those using the perpendicular spot during LIHC, respectively. By increasing laser scanning speed and powder feeding rate, the dilution of the composite coating by LIHC was decreased, the homogeneity of WC particles distribution was improved. As a result, the free-crack ceramic-metal composite coatings with a low dilution and high microhardness were obtained, with the weight fraction of WC particles higher than 35%wt and the metallurgical bonding between the composite coatings and the substrate.
The heat damage fashions and mechanisms of WC particle in Ni-based WC composite coatings by LIHC were studied in detail. The results proved that the formulas of half quantity on the heat damage level of WC particles introduced before can be adopted to evaluate the heat damage extent of WC particles in multi-pass overlapping Ni-based WC composite coatings if the high laser scanning speed was adopted during LIHC, which demonstrated that the formulas not only had an extensive application range and strong practicality, but also may provide an important theoretical basis to evaluate the microstructure and properties of laser-induction hybrid cladding Ni-based WC composite coatings.
When Ni-based alloy was used as the matrix alloy in ceramic-metal composite coatings by LIHC, the heat damage mechanisms of WC particles usually took the following models:
(1) The dissolution-diffusion heat damage fashion: WC particles were continually dissolved by the molten Ni-based alloy at high temperature and exchanged their atoms each other, which resulted in WC particles dissolveng directly into Ni-based alloy solution and then precipitated in the format of M_6C, M_(12)C and other carbides during the rapid solidification processing. In the meantime, the alloying elements such as Ni, Cr and Fe diffused into WC particles rapidly, thus forming an alloyed reaction layer with limited thickness.
(2) The dispersion-dissolution diffusion hybrid heat damage fashion: a part of WC particles with small size were dispersed into several small pieces of WC particles when they were irradiated by laser, which was heat damaged as the dissolution-diffusion heat damage fashion above mentioned. However, these dispersed WC particles with relatively smaller size may change into the alloyed carbides with high W concentration after they interacted with Ni-based alloy solution at high temperature.
(3) WC particles with relatively smaller size may dissolve into Ni-based alloy solution completely, and then precipitated into the composite coating in the format of carbides such as M_6C, M_(12)C, M_(23)C_6 and M_7C_3 with different morphology (i.e. blocky, bar-like and fish-bone shape).
The compositions of the matrix alloys have a big effect on the heat damage of the WC particles. It was found that WC particles had a complete dissolution in Fe-based WC composite coatings produced by LIHC. The coatings was composed of M_6C, M_(23)C_6 martensite and the retained austenite and the microhardness of the binder metal was lower than that in Ni-based WC composite coating under the same processing condtions. This result has not reported before. This difference was mainly caused by the difference of the dissolution level and rates of WC particles in the binder metal, melting point and latent heat between Ni-based and Fe-based alloy. The above results were highly helpful to choose a reasonable binder alloy.
The sliding wear resistance and mechanisms of Ni-based WC composite coatings and Fe-based composite coatings prepared by LIHC were studied systematically. The adhesion wear, abrasive wear, fatigue wear and oxidation wear were simultaneously found in the samples by dry sliding wear process of the ceramic-metal composite coatings, the debris with lamellar structure were sheared from the composite coatings by the delamination pattern. Especially, the heat damage extent of the WC particles had a big effect on the sliding wear resistance of the composite coatings. By increasing laser scanning speed, the wear resistance of Ni-based WC composite coatings by LIHC can be 1.4 times as much as that of Ni-based WC composite coatings by the laser cladding with the same composition of the alloying powders. The main reason was that increasing laser scanning speed can decrease the heat damage extent, which can increase the microhardness of the composite coatings, improve the homogeneous distribution of WC particles, decrease the average distance of WC particles and limit the plastic transformation of the binder.
In summary, the above results demonstrated that laser-induction hybrid cladding ceramic-metal composite coatings had more excellent propeties than the laser cladding ceramic-metal composite coatings with the same composition of alloy powders, which may find a wide application field in industrial area.
引文
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