CN116536665B - Method for rapidly preparing laser cladding functionally gradient coating and coating obtained by same - Google Patents
Method for rapidly preparing laser cladding functionally gradient coating and coating obtained by same Download PDFInfo
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Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
- C23C24/106—Coating with metal alloys or metal elements only
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/48—Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/58—Ferrous alloys, e.g. steel alloys containing chromium with nickel with more than 1.5% by weight of manganese
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Materials Engineering (AREA)
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- Organic Chemistry (AREA)
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- Other Surface Treatments For Metallic Materials (AREA)
Abstract
The invention belongs to the technical field of laser cladding coatings, and particularly relates to a method for rapidly preparing a laser cladding functionally gradient coating and the coating obtained by the method, which comprises the following steps: (1) Premixing a ceramic particle component and a first alloy powder; (2) Feeding the obtained premixed powder and the second alloy powder to the surface of a substrate according to respective powder feeding rates, and simultaneously carrying out laser cladding on the powder on the surface of the substrate to sequentially form a bottom layer, a transition layer and a functional layer on the surface of the substrate; the powder feeding rates of the corresponding premixed powders of the layers are respectively marked as X1, X2 and X3, the powder feeding rates of the second alloy powders are respectively marked as Y1, Y2 and Y3, and x2=aX (x1+ (X3-X1)/2), y2=bX (y1+ (Y3-Y1)/2), a=0.6-1.0 and b=1.0-1.2. The invention reduces the internal stress of each layer, improves the interface bonding strength, reduces the generation of cracks, and simultaneously combines proper high hardness.
Description
Technical Field
The invention belongs to the technical field of laser cladding coatings, and particularly relates to a method for rapidly preparing a laser cladding functionally gradient coating and the coating obtained by the method.
Background
The functional gradient coating material is a coating material with a gradient structure, which is prepared on a substrate by a surface processing method, and has unique superiority for improving the bonding strength of the coating and the substrate and endowing the material with a new function. An ideal functionally graded coating should be one that achieves complete compositional and structural gradients from the substrate to the coating surface. In the ceramic particle reinforced composite coating, the ceramic particles are distributed in a gradient manner, so that the effect of fully utilizing the characteristics of the ceramic particles and the alloy can be achieved, the residual stress can be effectively reduced, the accumulation of thermal stress can be relieved, and the generation tendency of cracks can be reduced.
The laser cladding is a surface modification technology developed in the 70 s of the 20 th century, and the principle is that the surface of cladding alloy powder and a metal matrix is rapidly melted, reacted and solidified by high-energy laser beam irradiation to form a cladding coating with special properties such as high hardness, wear resistance, corrosion resistance and the like. The laser cladding surface modification technology solves the problems that the traditional technological methods such as vibration welding, argon arc welding, spraying, plating and the like cannot solve the material selection limitation, the thermal stress, the thermal deformation, the matrix material bonding strength in the technological process are difficult to ensure and the like, can realize the metallurgical bonding of the coating and the matrix, refine the structure grains, can realize the surface cladding path planning of complex parts through programming, is convenient for industrialization, has wide prospect, and covers a plurality of industries such as mining machinery, petrochemical industry, electric power, railway, automobile, ship, metallurgy, aviation and the like.
The laser cladding functionally gradient coating has excellent performance, and one of the methods adopted in the current preparation of the functionally gradient coating is to put single ceramic powder and single alloy powder into different powder feeders, mix the ceramic powder and the single alloy powder on a line in the cladding process, and form a coating of a bottom layer and a functional layer on the surface of a substrate by adjusting the powder feeding rotating speed or the powder feeding speed. However, on one hand, the method easily causes uneven distribution of ceramic particles, and the ceramic particles start to be fully combined with the alloy after entering a molten pool, so that the interface combination strength of the ceramic particles and the alloy is affected; on the other hand, the powder feeding speed of the functional layer is directly adjusted from the corresponding powder feeding speed of the bottom layer, so that the coating is unevenly distributed inside, the bonding strength is low, and internal stress and cracks are easily generated.
Disclosure of Invention
The invention aims to overcome the defects that the coating is uneven and easy to crack and easy to fall off from a substrate caused by the existing method, and provides a method for rapidly preparing a laser cladding functionally gradient coating and the obtained coating.
To achieve the above object, in a first aspect, the present invention provides a method for rapidly preparing a laser cladding functionally graded coating, comprising the steps of:
(1) Premixing ceramic particle components and first alloy powder to obtain premixed powder; in the premixed powder, the mass content of the ceramic particle component is 40-90wt%, and the mass content of the first alloy powder is 10-60wt%;
(2) Feeding the premixed powder and the second alloy powder to the surface of a substrate according to respective powder feeding rates, and simultaneously carrying out laser cladding on the powder on the surface of the substrate to sequentially form a bottom layer, a transition layer and a functional layer on the surface of the substrate;
the powder feeding rates of the premixed powder are respectively marked as X1, X2 and X3 in the formation of the bottom layer, the transition layer and the functional layer, and the powder feeding rates of the second alloy powder are respectively marked as Y1, Y2 and Y3 in the formation of the bottom layer, the transition layer and the functional layer, so that the premixed powder meets the following conditions: x2=a× (x1+ (X3-X1)/2), y2=b× (y1+ (Y3-Y1)/2), wherein a=0.6-1.0, b=1.0-1.2.
Preferably, when the ceramic particle component in the pre-mixed powder is 40-55wt%, a=0.95-1.0, b=a; when the ceramic particle component in the pre-mixed powder is 56-75wt%, a=0.8-0.9, b=1.0-1.1; when the ceramic particle component in the pre-mixed powder is 76-90wt%, a=0.6-0.7 and b=1.1-1.2.
In some preferred embodiments of the invention, X1 is 0-38g/min, X3 is 14-114 g/min, Y1 is 40-60 g/min, and Y3 is 0-50g/min.
In some preferred embodiments of the invention, the total thickness of the transition layer = c x n x functional layer thickness, n being the total number of transition layers; wherein, when n=1, c=0.5-1.2; when n is not less than 2, c is 0.5 to 0.8, and c decreases with an increase in n.
In some preferred embodiments of the present invention, the transition layer is one or more than two, the total number of transition layers is N, the number of layers per layer is N, and the powder feeding rate of the premixed powder of the Nth transition layer is X 2N The powder feeding rate of the second alloy powder of the corresponding layer is marked as Y 2N The method comprises the following steps: x is X 2N =X1+N×(X3-X1)/(n+1)，Y 2N =Y1+N×(Y3-Y1)/(n+1)。
In some preferred embodiments of the present invention, in step (2), the feeding of the premixed powder and the second alloy powder to the surface of the substrate at respective feeding rates includes:
firstly, dividing the premixed powder to form a plurality of first powder bundles which are uniformly distributed along the circumferential direction; meanwhile, the second alloy powder is divided into a plurality of second powder bundles which are uniformly distributed along the circumferential direction;
the first powder beam and the second powder beam are coaxially arranged at intervals and are fed to the surface of the substrate according to respective powder feeding rates.
More preferably, the method employs an apparatus comprising:
the laser cladding mechanism is arranged close to the surface of the matrix;
the premixed powder feeder comprises a first powder feeding tank, a first-stage powder feeding pipe A, a first powder dividing unit and a second-stage powder feeding pipe A which are sequentially communicated; the two-stage powder feeding pipes A are in a plurality, and inlets of the two-stage powder feeding pipes A are communicated with the first powder separating unit;
the second alloy powder feeder comprises a second powder feeding tank, a first-stage powder feeding pipe B, a second powder dividing unit and a second-stage powder feeding pipe B which are sequentially communicated; the second-level powder feeding pipes B are a plurality of and the inlets of the second-level powder feeding pipes B are communicated with the second powder dividing unit;
the coaxial powder feeding nozzle is provided with a plurality of powder feeding channels, the secondary powder feeding pipes A and the secondary powder feeding pipes B are coaxially arranged at intervals along the circumferential direction of the shaft, and the outlets of the secondary powder feeding pipes A and the secondary powder feeding pipes B are respectively communicated with the inlets of the powder feeding channels in a one-to-one correspondence manner; outlets of the powder feeding channels are close to the surface of the matrix.
In some preferred embodiments of the present invention, in step (1), the ceramic particle component comprises: first ceramic particles having a particle size of 0.5 to 3 μm, second ceramic particles having a particle size of 15 to 45 μm, and third ceramic particles having a particle size of 90 to 150 μm; the mass of the premixed powder is 10-20wt% of the first ceramic particles, 10-30wt% of the second ceramic particles and 20-40wt% of the third ceramic particles.
In some preferred embodiments of the present invention, the first alloy powder and the second alloy powder each independently satisfy: the particle size is 53-150 μm, the average particle size D50 is 65-85 μm, and the fluidity is 25-35s/100g.
In some preferred embodiments of the present invention, the composition of the first alloy powder and the second alloy powder each independently comprises: and C:0.7-1wt%, cr:17-20wt%, ni:4-5wt%, mn less than or equal to 1wt%, mo:1-2wt%, B:1-2wt% of Si less than or equal to 1wt%, nb:2-3wt% and the balance of Fe.
In some preferred embodiments of the present invention, in step (1), the premixing process comprises: mixing for 120-240min, and heating at 70-100deg.C for 2-3 hr.
In some preferred embodiments of the present invention, in step (2), the conditions of the laser cladding include: the laser power is 1400-3000W, and the scanning speed is 4-20mm/s.
In a second aspect, the invention provides a laser cladding functionally graded coating, which is prepared by the method of the first aspect, and which comprises a primer layer, a transition layer and a functional layer which are arranged in sequence, wherein the interior and the surface of the coating are free of cracks.
Advantageous effects
According to the technical scheme, particularly, powder is mixed on line, the powder feeding rate is regulated to a proper value in real time, a specific transition layer structure can be prepared between the bottom layer and the functional layer of the coating, and the transition layer structure can reduce the differences in interfaces and components between gradient layers in the coating and between the coating and a matrix, so that the internal stress caused by the differences of the thermal expansion coefficient and the lattice constant between the gradient layers is reduced, the interface bonding strength is improved, the generation of cracks is reduced, and meanwhile, the high hardness is suitable; the constant factors a and b in the powder feeding rate formula of each gradient layer are suitable ranges obtained based on a large amount of researches on the thermal expansion coefficient, the lattice constant difference and the like of each gradient layer and the interface bonding strength of the gradient layers, so that the interface bonding strength between each gradient layer and between a coating and a substrate under the structure with a specific transition layer is improved, and the use requirement is met; under the same conditions, the constant factors a and/or b are not in the scope of the invention, so that the content of ceramic particles and alloy components among the gradient layers cannot be uniformly transited, or the stress accumulation is cracked or the thickness of the layers cannot be well controlled due to the volume difference of materials caused by the different content of the ceramic particles in the transition layers, thereby affecting the cladding effect.
In addition, the ceramic particle components and the first alloy powder are premixed first and then mixed with the second alloy powder in real time, so that all the alloy powder can enter a molten pool more uniformly, the ceramic particles are distributed more uniformly, the interface bonding strength between the ceramic particles and the alloy is obviously enhanced, the internal stress of a coating is reduced, and the possibility of crack generation is further avoided.
The invention changes the traditional preparation mode of one-step mixing of one component of the composite powder laser cladding, reduces powder loss, reduces material waste and improves production efficiency.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic view showing the structure of the pre-mixed powder feeder, the second alloy powder feeder and the coaxial powder feeding nozzle of the present invention in cooperation with each other.
FIG. 2 is a morphology electron microscope image of the functionally graded coating obtained in example 1 of the present invention.
FIG. 3 is a macroscopic picture of the functionally graded coating obtained in example 1 of the present invention.
FIG. 4 is a topographical electron micrograph of the cladding coating without the transition layer obtained in comparative example 1.
Fig. 5 is a macroscopic picture of the cladding coating without the transition layer obtained in comparative example 1.
Description of the reference numerals
1. The device comprises a first powder feeding tank, a second powder feeding tank, a first-stage powder feeding pipe A, a first-stage powder feeding pipe B, a first powder dividing unit, a second powder dividing unit, a first-stage powder feeding pipe A, a second-stage powder feeding pipe B, a coaxial powder feeding nozzle and a coaxial powder feeding nozzle.
Detailed Description
The endpoints and any values of the ranges disclosed herein are not limited to the precise range or value, and are understood to encompass values approaching those ranges or values. For numerical ranges, one or more new numerical ranges may be found between the endpoints of each range, between the endpoint of each range and the individual point value, and between the individual point value, in combination with each other, and are to be considered as specifically disclosed herein. Wherein the terms "optional" and "optionally" mean either comprising or not comprising (or may not be present).
In a first aspect, the invention provides a method for rapidly preparing a laser cladding functionally graded coating, comprising the steps of:
(1) Premixing ceramic particle components and first alloy powder to obtain premixed powder; in the premixed powder, the mass content of the ceramic particle component is 40-90wt%, and the mass content of the first alloy powder is 10-60wt%;
(2) Feeding the premixed powder and the second alloy powder to the surface of a substrate according to respective powder feeding rates, and simultaneously carrying out laser cladding on the powder on the surface of the substrate to sequentially form a bottom layer, a transition layer and a functional layer on the surface of the substrate;
the powder feeding rates of the premixed powder are respectively marked as X1, X2 and X3 in the formation of the bottom layer, the transition layer and the functional layer, and the powder feeding rates of the second alloy powder are respectively marked as Y1, Y2 and Y3 in the formation of the bottom layer, the transition layer and the functional layer, so that the premixed powder meets the following conditions: x2=a× (x1+ (X3-X1)/2), y2=b× (y1+ (Y3-Y1)/2), wherein a=0.6-1.0, b=1.0-1.2.
Preferably, when the ceramic particle component in the pre-mixed powder is 40-55wt%, a=0.95-1.0, b=a; when the ceramic particle component in the pre-mixed powder is 56-75wt%, a=0.8-0.9, b=1.0-1.1; when the ceramic particle component in the pre-mixed powder is 76-90wt%, a=0.6-0.7 and b=1.1-1.2. Under the preferred scheme, the relation between the gap between the total content of the ceramic particles of the functional layer and the total content of the ceramic particles of the bottom layer, the interface bonding strength and the stress is fully considered, and a proper constant factor is adapted according to different gap levels, so that the residual stress can be further reduced to reduce the possibility of cracking, and meanwhile, the integral powder feeding rate of the cladding layer can be ensured to be kept stable, thereby being more beneficial to realizing good transition.
In some more preferred embodiments of the invention, a=1.0, b=1.0 when the ceramic particle component in the pre-mixed powder is 40-55 wt%; when the ceramic particle component in the pre-mixed powder is 56-75wt%, a=0.8, b=1.1; when the ceramic particle component in the pre-mixed powder is 76-90wt%, a=0.6, b=1.2.
It should be understood that the functional gradient of the present invention may be distributed in the horizontal direction or in the thickness direction, and the effect of the present invention can be achieved by forming a specific transition layer according to the above powder feeding rate and in combination with other features, no matter in which direction the gradient is distributed.
In the invention, in the process of rapidly preparing the laser cladding functionally graded coating, the powder feeding rate of the premixed powder and the second alloy powder is kept stable and unchanged respectively in the process of forming each layer, and the corresponding powder feeding rate required for directly adjusting to the subsequent layer after the formation of the previous layer is kept stable and unchanged continuously to form the subsequent layer, namely, the corresponding powder feeding rate is kept unchanged in the process of forming the same layer, so that the performance of the layer is kept consistent.
The invention adopts the ceramic particle component and the first alloy powder to prepare the premixed powder, so that the problems of uneven powder feeding and low ceramic particle bonding strength caused by separate powder feeding of single ceramic particles and single alloy powder are avoided.
In some preferred embodiments of the invention, X1 is 0-38g/min, X3 is 14-114 g/min, Y1 is 40-60 g/min, and Y3 is 0-50g/min. Under the preferred scheme, the ceramic particles are proper in content, the thermal expansion coefficients of the substrate and the cladding coating are more matched, and the possibility of occurrence of macroscopic cracks on the surface of the cladding coating can be further avoided.
In some preferred embodiments of the invention, the total thickness of the transition layer = c x n x functional layer thickness, n being the total number of transition layers; wherein, when n=1, c=0.5-1.2; when n is not less than 2, c is 0.5 to 0.8, and c decreases with an increase in n. In the preferred scheme, on one hand, the possibility that the effect of the transition layer is affected due to the fact that the bottom layer elements are melted into the transition layer due to the fact that the transition layer is melted through by laser can be avoided; on the other hand, the thermal stress is further reduced under the condition of lower cost, so that the possibility of cracking the cladding functional layer is avoided; and the transition of the components is more uniform.
In the present invention, the thickness of the transition layer is preferably substantially equal to that of the functional layer when the transition layer is a single layer, and the thickness may slightly float due to the difference of the material densities, so that more preferably, when n=1, c=0.8 to 1, which is more advantageous for uniform transition.
More preferably, n=1-3, which is more advantageous for reducing stress accumulation, further avoiding the possibility of cracking.
In some more preferred embodiments of the present invention, when n=1, c=0.5-1.2, where c=1 is most preferred; as n increases, c gradually decreases, e.g., when n=2, c=0.8, and when n+.3, c=0.5. Under the preferred scheme, the composition transition can be made more uniform.
The transition layer of the invention can be one or more layers. In some preferred embodiments of the present invention, the transition layer is one or more than two, the total number of transition layers is N, the number of layers per layer is N, and the powder feeding rate of the premixed powder of the Nth transition layer is X 2N The powder feeding rate of the second alloy powder of the corresponding layer is marked as Y 2N The method comprises the following steps: x is X 2N =X1+N×(X3-X1)/(n+1)，Y 2N =y1+nx (y3—y1)/(n+1). Under the preferred scheme, the composition between gradient layers in the coating and between the coating and the matrix can be smoothly transited, so that the internal stress caused by the difference of the thermal expansion coefficient and the lattice constant between the gradient layers is reduced, the interface bonding strength is further improved, and the generation of cracks is further reduced.
Illustratively, in a specific embodiment, the total number of transition layers is N, the number of layers per layer is N, for example, if the total number of transition layers is 3, n=3, the first layer n=1, the second layer n=2, the third layer n=3, and so on. For example, the transition layer is 2 layers, the powder feeding rate X1 of the bottom layer and the powder feeding rate X3 of the functional layer are respectively 1g/min and 4g/min, n=2, the first layer n=1, and the powder feeding rate is X 21 =1+1× (4-1)/(2+1) =2 g/min; the second layer N=2, the powder feeding rate is X 22 =1+2×（4-1）/（2+1）=3g/min。
In some preferred embodiments of the present invention, in step (2), the feeding of the premixed powder and the second alloy powder to the surface of the substrate at respective feeding rates includes:
firstly, dividing the premixed powder to form a plurality of first powder bundles which are uniformly distributed along the circumferential direction; meanwhile, the second alloy powder is divided into a plurality of second powder bundles which are uniformly distributed along the circumferential direction;
the first powder beam and the second powder beam are coaxially arranged at intervals and are fed to the surface of the substrate according to respective powder feeding rates.
In the preferred scheme, the method for carrying out powder feeding and on-line mixing after coaxial powder feeding on the premixed powder and the single second alloy powder respectively can respectively adjust the powder feeding rate, so that the laser cladding functional gradient coating with ceramic particles distributed in a gradient manner is prepared on the surface of the substrate, the complicated process of configuring one part of premixed powder in a gradient manner is reduced, and the waste of the premixed powder is effectively reduced. Meanwhile, the premixed powder and the second alloy powder are synchronously fed, on-line mixing is carried out, and the ceramic particles and the alloy powder begin to absorb laser energy to react before entering a molten pool, so that the problems of uneven ceramic particle distribution, low interface bonding strength of the ceramic particles and the alloy and the like caused by feeding of single ceramic particles and single alloy powder are avoided; and the difference between the inside of the coating and the substrate can be further reduced, and the possibility of internal stress and crack occurrence is reduced.
More preferably, the method employs an apparatus comprising: the laser cladding mechanism is arranged close to the surface of the matrix; as shown in fig. 1, further includes:
the premixed powder feeder comprises a first powder feeding tank 1, a first-stage powder feeding pipe A3, a first powder dividing unit 5 and a second-stage powder feeding pipe A7 which are sequentially communicated; the number of the secondary powder feeding pipes A7 is several, and the inlets of the secondary powder feeding pipes A7 are communicated with the first powder separating unit 5;
the second alloy powder feeder comprises a second powder feeding tank 2, a first-stage powder feeding pipe B4, a second powder dividing unit 6 and a second-stage powder feeding pipe B8 which are sequentially communicated; the number of the secondary powder feeding pipes B8 is several, and the inlets of the secondary powder feeding pipes B8 are communicated with the second powder dividing unit 6;
the coaxial powder feeding nozzle 9 is provided with a plurality of powder feeding channels, the secondary powder feeding pipe A7 and the secondary powder feeding pipe B8 are coaxially arranged at intervals along the circumferential direction of the shaft, and the outlets of the coaxial powder feeding nozzle are respectively communicated with the inlets of the powder feeding channels in a one-to-one correspondence manner; outlets of the powder feeding channels are close to the surface of the matrix. It will be appreciated that the secondary powder feeding pipe A7 and the secondary powder feeding pipe B8 are coaxially ejected through the corresponding powder feeding passages, without secondary mixing in the coaxial powder feeding nozzle 9.
In the above preferred scheme, only mixing powder is performed in each powder separating unit, and the coaxial powder feeding nozzle 9 is not used for mixing, but a plurality of powder feeding channels are not communicated with each other, and the powder feeding channels are respectively and directly communicated with the corresponding secondary powder feeding pipes and coaxially ejected, so that the uniformity of powder feeding gas and powder is better maintained. If the secondary mixing is performed in the coaxial powder feeding nozzle 9, powder may be accumulated, and the uniformity effect may be poor.
In some specific embodiments, the premixed powder is placed in a first powder feeding tank 1, the second alloy powder is placed in a second powder feeding tank 2, after laser cladding is started, the first powder feeding tank 1 is fed into a first powder dividing unit 5 through a first-stage powder feeding pipe A3 and then uniformly distributed to a second-stage powder feeding pipe A7, and the second powder feeding tank 2 is fed into a second powder dividing unit 6 through a first-stage powder feeding pipe B4 and then uniformly distributed to a plurality of second-stage powder feeding pipes B8; and then the powder is respectively and coaxially sprayed out through the powder conveying channels of the coaxial powder conveying nozzle 9, and the powder conveying channels are coaxially and uniformly distributed at intervals, so that the powder conveying is more uniform.
In some preferred embodiments of the present invention, in step (2), the conditions of the laser cladding include: the laser power is 1400-3000W, and the scanning speed is 4-20mm/s. Under the preferable scheme, the powder can be subjected to laser cladding by matching with the powder feeding speed, so that a functional gradient coating can be formed rapidly.
In the present invention, a person skilled in the art may also set other conventional conditions in the laser cladding, for example, the conditions of the laser cladding further include: the laser cladding is carried out in the presence of inert gas (such as argon), the flow rate of the argon is 15-25L/min, and the lap joint rate is 40-50%.
In some preferred embodiments of the present invention, in step (1), the ceramic particle component comprises: first ceramic particles having a particle size of 0.5 to 3 μm, second ceramic particles having a particle size of 15 to 45 μm, and third ceramic particles having a particle size of 90 to 150 μm; the mass of the premixed powder is 10-20wt% of the first ceramic particles, 10-30wt% of the second ceramic particles and 20-40wt% of the third ceramic particles. Under the preferred scheme, the multi-scale ceramic particle component is selected to replace ceramic particles with single granularity, so that the coupling enhancement effect can be achieved, wherein 0.5-3 mu m of fine first ceramic particles are easy to attach to the surface of large-size first alloy powder in the premixing process, and are easy to fuse to the surface of the first alloy powder in the cladding process, so that a certain surface modification effect is achieved, and the hetero-interface combination property of the large-size ceramic particles and the first alloy powder is optimized; the third ceramic particles with the diameter of 90-150 mu m mainly play a role in improving the wear resistance of the cladding coating, and the second ceramic particles with the diameter of 15-45 mu m are filled among the third ceramic particles with the diameter of 90-150 mu m, so that the effect of relieving stress can be achieved.
The ceramic particles of the present invention may be any type of ceramic known in the art, for example, one or more of titanium carbide, tungsten carbide, niobium carbide, vanadium carbide and chromium carbide may be used.
In some preferred embodiments of the present invention, the first alloy powder and the second alloy powder each independently satisfy: the particle size is 53-150 μm, the average particle size D50 is 65-85 μm, and the fluidity is 25-35s/100g.
In some preferred embodiments of the present invention, the composition of the first alloy powder and the second alloy powder each independently comprises: and C:0.7-1wt%, cr:17-20wt%, ni:4-5wt%, mn less than or equal to 1wt%, mo:1-2wt%, B:1-2wt% of Si less than or equal to 1wt%, nb:2-3wt% and the balance of Fe.
The first alloy powder and the second alloy powder of the present invention may be the same or different, and may be any type of alloy existing in the art, for example, any one of austenitic stainless steel, martensitic stainless steel, duplex stainless steel, and nickel-based self-fluxing alloy may be selected independently of each other.
In some preferred embodiments of the present invention, in step (1), the premixing process comprises: mixing for 120-240min, and heating at 70-100deg.C for 2-3 hr.
The substrate of the invention can be various alloy steel substrates. Other conventional steps may be performed as desired by those skilled in the art, for example, the method of the present invention may further comprise: the surface of the substrate is polished (e.g., with an angle grinder) and washed with an organic solvent (e.g., acetone) prior to the laser cladding.
In a second aspect, the invention provides a laser cladding functionally graded coating, which is prepared by the method of the first aspect, and which comprises a primer layer, a transition layer and a functional layer which are arranged in sequence, wherein the interior and the surface of the coating are free of cracks.
The invention will be further described in detail with reference to specific examples.
Example 1
A method for rapidly preparing a laser cladding functionally graded coating comprises the following steps:
pretreatment of a matrix: polishing the surface of the 45# substrate by an angle grinder and cleaning the surface by acetone to obtain a flat and clean surface;
preparation of premixed powder: mixing the first alloy powder and the multi-scale WC powder in a mixer for 180min according to a certain mass percentage, heating for 2h at 80 ℃ after uniformly mixing, and drying to obtain premixed powder; wherein, the mass percent of the premixed powder is 10 percent of ceramic particles with the diameter of 0.5-3 mu m, 10 percent of ceramic particles with the diameter of 15-45 mu m, 40 percent of ceramic particles with the diameter of 90-150 mu m and the balance of the first alloy powder. The mass percentages of the elements of the first alloy powder are C:0.75%, cr:18.25%, ni:4.50%, mn: less than or equal to 1 percent, mo:1.23%, B:1.14 percent, si is less than or equal to 1 percent, nb:2.33% and the balance of Fe. The particle size of the first alloy powder ranged from 53 to 150 μm, the average particle size D50 was 73.6 μm, and the flowability was 28.4s/100g.
And (3) rapidly preparing a laser cladding functionally-gradient coating: respectively placing the premixed powder and the second alloy powder (with the same composition as the first alloy powder) into two powder feeders in the device shown in figure 1, adjusting laser cladding process parameters under the protection of argon, preparing cladding coating on the surface of a substrate by adopting a coaxial powder feeding laser cladding mode, and slowly adjusting the rotating speed of the powder feeders to start after one layer cladding is completedAnd cladding the next layer. CO for laser cladding 2 The laser processing system adopts the process that the laser power is 2400W, the scanning speed is 20mm/s, the lap joint rate is 50%, the argon flow is 20L/min, the first layer is the bottom layer, the powder feeding rate of the powder feeder 1 is 0g/min, the powder feeding rate of the powder feeder 2 is 60g/min, and the thickness of the bottom layer is 0.8mm; a transition layer is arranged above the bottom layer, so that components are more uniformly transited, the thickness of the transition layer=the thickness of the functional layer=0.7 mm, the powder feeding rate of the powder feeder 1 is 32g/min (a=0.8 at the moment), and the powder feeding rate of the powder feeder 2 is 38.5g/min (b=1.1 at the moment); the third layer is a functional layer, the powder feeding rate of the powder feeder 1 is 80g/min, and the powder feeding rate of the powder feeder 2 is 10g/min.
The internal topography of the coating obtained in this embodiment is shown in fig. 2, and the surface macroscopic view is shown in fig. 3, so that it can be seen that the interior and the surface of the obtained coating have no cracks and the internal transition is uniform.
Example 2
With reference to example 1, the difference is that the powder feeding rate is different and the structure of the coating is different, specifically, the first layer is a bottom layer, the powder feeding rate of the powder feeder 1 is 0g/min, and the powder feeding rate of the powder feeder 2 is 60g/min; the second layer and the third layer are transition layers, the total thickness of the transition layers=0.8x2xfunctional layer thickness, when the second layer is prepared, the powder feeding rate of the powder feeder 1 is 26.7g/min, the powder feeding rate of the powder feeder 2 is 43.3g/min, and when the third layer is prepared, the powder feeding rate of the powder feeder 1 is 53.3g/min, and the powder feeding rate of the powder feeder 2 is 26.7g/min; the fourth layer is a functional layer, the rotating speed of the powder feeder 1 is 80g/min, the rotating speed of the powder feeder 2 is 10g/min, and the thickness of the functional layer is 0.7mm.
In the embodiment, the gradient of the change of the thermal expansion coefficient is slowed down through the two transition layers, the interior and the surface of the cladding coating are free from cracks, and the interior transition is uniform.
Example 3
With reference to example 1, except that the target powder feeding rate of the transition layer was different, the powder feeding rate of the powder feeder 1 was adjusted to 40g/min (at this time a=1.0) while the powder feeding rate of the powder feeder 2 was adjusted to 35g/min (at this time b=1.0) at the time of preparing the transition layer.
Example 4
Reference example 1 was followed except that the transition layer thickness=1/2 of the functional layer thickness (c=0.5 in this case).
Example 5
With reference to example 1, except that the premix powder comprises, in mass percent, 0.5 to 3 μm ceramic particles 5%,15 to 45 μm ceramic particles 5%,90 to 150 μm ceramic particles 40%, the balance being the first alloy powder; when the transition layer is prepared, the powder feeding rate of the powder feeder 1 is 40g/min (a=1.0 at the moment), and the powder feeding rate of the powder feeder 2 is 35g/min (b=1.0 at the moment).
Example 6
With reference to example 1, except that the premix powder comprises, in mass percent, 0.5 to 3 μm ceramic particles 5%,15 to 45 μm ceramic particles 5%,90 to 150 μm ceramic particles 40%, the balance being the first alloy powder; the preparation process of the transition layer is unchanged.
Example 7
With reference to example 1, except that the premix powder comprises, in mass percent, 25% of ceramic particles of 0.5 to 3 μm, 15% of ceramic particles of 15 to 45 μm, 40% of ceramic particles of 90 to 150 μm, and the balance of the first alloy powder; when the transition layer is prepared, the powder feeding rate of the powder feeder 1 is 24g/min (a=0.6 at the moment), and the powder feeding rate of the powder feeder 2 is 42g/min (b=1.2 at the moment).
Example 8
With reference to example 1, except that the premix powder comprises, in mass percent, 25% of ceramic particles of 0.5 to 3 μm, 15% of ceramic particles of 15 to 45 μm, 40% of ceramic particles of 90 to 150 μm, and the balance of the first alloy powder; the preparation process of the transition layer is unchanged.
Example 9
With reference to example 2, except that in the preparation of the third layer, the powder feeding rate of the powder feeder 1 was 53.3g/min and the powder feeding rate of the powder feeder 2 was 20g/min.
Comparative example 1
With reference to example 1, except that the powder feeding rate is different and the coating structure is different, no transition layer is provided; specifically, the first layer is a bottom layer, the rotating speed of the powder feeder 1 is 0g/min, and the rotating speed of the powder feeder 2 is 60g/min; the second layer is a functional layer, the rotating speed of the powder feeder 1 is 80g/min, and the rotating speed of the powder feeder 2 is 10g/min.
The internal appearance diagram of the obtained coating is shown in fig. 4, the surface macroscopic diagram is shown in fig. 5, and it can be seen that the interface components between the internal bottom layer and the functional layer of the obtained coating are greatly different, and vertical cracks exist on the surface of the obtained coating.
Comparative example 2
With reference to example 1, the difference is that the powder feeding rate of the transition layer is different, specifically, when the transition layer is prepared, the powder feeding rate of the powder feeder 1 is adjusted to 20g/min, and the powder feeding rate of the powder feeder 2 is adjusted to 45g/min.
Test case
The coatings obtained in the examples and the comparative examples are subjected to performance tests, and the surface hardness of the cladding coating is tested by using an HRN/T150 Rockwell hardness tester. And residual stress test was performed on the prepared cladding coating by using a D8 ADVANCE X-ray diffractometer (XRD) manufactured by BRUKER corporation of Germany; the residual stress testing principle is as follows: when residual stress exists in the sample, the interplanar spacing is changed, bragg diffraction occurs, the generated diffraction peak is also moved along with the variation, and the moving distance is related to the stress; the testing method comprises the following steps: using X-ray with wavelength lambda to irradiate the sample with different incidence angles for several times, measuring the corresponding diffraction angle 2 theta, and obtaining the slope M of 2 theta to sin2 psi to calculate the residual stress sigma phi; the equipment has an operation acceleration voltage of 40 kV, an operation current of 40 mA, an X-ray diffraction angle of 2 theta = 20-90 degrees, a step length of 0.02 degrees and a scanning speed of 12 degrees/min by using a Cu target (1.54184A) K alpha ray. The test results are shown in table 1 below.
TABLE 1
Compared with comparative examples 1-2, the embodiment of the invention containing the proper transition layer can ensure that the components between gradient layers in the coating and between the coating and the matrix are smoothly transited under the condition of ensuring that the surface of the product is free from cracks, thereby being beneficial to reducing the internal stress (residual stress) caused by the difference of the thermal expansion coefficient and the lattice constant and improving the interface bonding strength; while maintaining a suitably high hardness. Whereas the products of comparative examples 1-2 had cracks on the surface, which resulted in cracking of the sample due to too high residual stress, after which the hardness was significantly reduced and unusable, and residual stress was released.
Further, according to example 1 and examples 3 to 4, the preferred embodiment 1 of the present invention can improve the hardness, at the same time, is more advantageous for reducing the residual stress, further improving the interface bonding strength, and ensuring no crack generation, and further improving the hardness. According to examples 5 and 6, or according to examples 7 and 8, it is found that the use of the present invention, which preferably provides a specific powder feeding rate, is more advantageous in reducing residual stress, improving hardness, and ensuring no crack generation. According to the embodiment 2 and the embodiment 9, the adoption of the multi-layer transition layer scheme with the optimized specific powder feeding rate is more beneficial to reducing residual stress, improving hardness and ensuring no crack.
The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited thereto. Within the scope of the technical idea of the invention, a number of simple variants of the technical solution of the invention are possible, including combinations of the individual technical features in any other suitable way, which simple variants and combinations should likewise be regarded as being disclosed by the invention, all falling within the scope of protection of the invention.
Claims (6)
1. The method for rapidly preparing the laser cladding functionally graded coating is characterized by comprising the following steps of:
(1) Premixing ceramic particle components and first alloy powder to obtain premixed powder; in the premixed powder, the mass content of the ceramic particle component is 40-90wt%, and the mass content of the first alloy powder is 10-60wt%;
(2) The premixed powder and the second alloy powder are respectively fed to the surface of a matrix according to respective powder feeding rates, synchronous powder feeding is carried out on the premixed powder and the second alloy powder, on-line mixing is carried out, and ceramic particle components and the alloy powder start to absorb laser energy to react before entering a molten pool; simultaneously carrying out laser cladding on each powder on the surface of the matrix, and sequentially forming a bottom layer, a transition layer and a functional layer on the surface of the matrix;
the powder feeding rates of the premixed powder are respectively marked as X1, X2 and X3 in the formation of the bottom layer, the transition layer and the functional layer, and the powder feeding rates of the second alloy powder are respectively marked as Y1, Y2 and Y3 in the formation of the bottom layer, the transition layer and the functional layer, so that the premixed powder meets the following conditions: x2=a× (x1+ (X3-X1)/2), y2=b× (y1+ (Y3-Y1)/2), X1 is 0-38g/min, X3 is 14-114 g/min, Y1 is 40-60 g/min, and Y3 is 0-50g/min;
wherein a=0.95 to 1.0 and b=a when the ceramic particle component in the premixed powder is 40 to 55 wt%;
when the ceramic particle component in the pre-mixed powder is 56-75wt%, a=0.8-0.9, b=1.0-1.1;
a=0.6 to 0.7 and b=1.1 to 1.2 when the ceramic particle component in the premixed powder is 76 to 90 wt%;
feeding the premixed powder and the second alloy powder to the surface of the substrate at respective feeding rates, comprising:
firstly, dividing the premixed powder to form a plurality of first powder bundles which are uniformly distributed along the circumferential direction; meanwhile, the second alloy powder is divided into a plurality of second powder bundles which are uniformly distributed along the circumferential direction;
the first powder beam and the second powder beam are coaxially arranged at intervals and are fed to the surface of the substrate through a coaxial powder feeding nozzle according to respective powder feeding rates.
2. The method according to claim 1, wherein the total thickness of the transition layer = c x n x functional layer thickness, n being the total number of layers of the transition layer; wherein, when n=1, c=0.5-1.2; when n is not less than 2, c is 0.5 to 0.8, and c decreases with an increase in n.
3. The method according to claim 1, wherein the method employs an apparatus comprising:
the laser cladding mechanism is arranged close to the surface of the matrix;
the premixed powder feeder comprises a first powder feeding tank, a first-stage powder feeding pipe A, a first powder dividing unit and a second-stage powder feeding pipe A which are sequentially communicated; the two-stage powder feeding pipes A are in a plurality, and inlets of the two-stage powder feeding pipes A are communicated with the first powder separating unit;
the second alloy powder feeder comprises a second powder feeding tank, a first-stage powder feeding pipe B, a second powder dividing unit and a second-stage powder feeding pipe B which are sequentially communicated; the second-level powder feeding pipes B are a plurality of and the inlets of the second-level powder feeding pipes B are communicated with the second powder dividing unit;
the coaxial powder feeding nozzle is provided with a plurality of powder feeding channels, the secondary powder feeding pipes A and the secondary powder feeding pipes B are coaxially arranged at intervals along the circumferential direction of the shaft, and the outlets of the secondary powder feeding pipes A and the secondary powder feeding pipes B are respectively communicated with the inlets of the powder feeding channels in a one-to-one correspondence manner; outlets of the powder feeding channels are close to the surface of the matrix.
4. The method according to claim 1, wherein in step (1),
the ceramic particle composition comprises: first ceramic particles having a particle size of 0.5 to 3 μm, second ceramic particles having a particle size of 15 to 45 μm, and third ceramic particles having a particle size of 90 to 150 μm; the mass of the premixed powder is 10-20wt% of the first ceramic particles, 10-30wt% of the second ceramic particles and 20-40wt% of the third ceramic particles;
the first alloy powder and the second alloy powder each independently satisfy: particle size range is 53-150 μm, average particle size D50 is 65-85 μm, fluidity is 25-35s/100g; the composition of the first alloy powder and the second alloy powder each independently includes: and C:0.7-1wt%, cr:17-20wt%, ni:4-5wt%, mn less than or equal to 1wt%, mo:1-2wt%, B:1-2wt% of Si less than or equal to 1wt%, nb:2-3wt% and the balance of Fe.
5. The method of claim 1, wherein in step (1), the premixing process comprises: firstly mixing for 120-240min, and then heating for 2-3h at 70-100 ℃;
and/or, in the step (2), the conditions of the laser cladding include: the laser power is 1400-3000W, and the scanning speed is 4-20mm/s.
6. A functionally graded laser cladding coating prepared by the method of any one of claims 1-5 and comprising a primer layer, a transition layer and a functional layer arranged in sequence, the coating being crack-free in its interior and surface.
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| CN109207995A (en) * | 2018-11-05 | 2019-01-15 | 山东科技大学 | A kind of high throughput abrasion resistant materials plasma cladding preparation system and its implementation |
| CN210475531U (en) * | 2019-09-09 | 2020-05-08 | 鑫精合激光科技发展（北京）有限公司 | Laser deposition additive manufacturing equipment for functional gradient material |
| CN112676580A (en) * | 2020-12-29 | 2021-04-20 | 天津辉锐激光科技有限公司 | Powder feeding system with powder mixing function |
| CN114045484A (en) * | 2021-10-26 | 2022-02-15 | 矿冶科技集团有限公司 | Multi-scale ceramic particle coupling enhanced laser cladding iron-based wear-resistant coating and preparation method thereof |
| CN115011960A (en) * | 2022-06-11 | 2022-09-06 | 丹阳飞超激光科技有限公司 | Coaxial broadband laser powder feeding nozzle |
| CN115369400A (en) * | 2022-07-26 | 2022-11-22 | 深圳大学 | Tungsten armor applied to first wall of cladding of nuclear fusion device and preparation method thereof |
| CN116083901A (en) * | 2023-01-07 | 2023-05-09 | 矿冶科技集团有限公司 | Reinforced phase distribution state adjustable laser cladding composite layer and preparation method thereof |
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