Mohsan Aziz Ul Hassan, Zhang Mina, Wang Dafeng, Wang Yishen, Zhang Jiahao, Zhou Yanyuan, Li Yifei, Zhao Su
Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, China.
International College, University of Chinese Academy of Sciences, Beijing 101408, China.
Materials (Basel). 2024 Feb 20;17(5):969. doi: 10.3390/ma17050969.
The design of the resonant ultrasonic vibration-assisted laser cladding (R-UVALC) setup involved employing finite element analysis (FEA) to simulate the ultrasonic transducer, horn, and workpiece in a resonance state. The impact of R-UVALC on AlCrFeMnNi high-entropy alloys was assessed using various ultrasonic vibration amplitudes of 0, 5, 10, and 15 µm, with a constant frequency of 20 kHz. Ultrasonic vibrations reduced pores and cracks and increased the clad breadth, melt pool wetting angle, and laser-clad layer consistency. The columnar elongated grains in proximity to the substrate surface underwent a size reduction and transformed into grains with a more equiaxed shape with the utilization of ultrasonic vibrations at an amplitude of 5 µm. Laser cladding performed without ultrasonic vibrations yields two phases: face-centered cubic (FCC) and body-centered cubic (BCC). However, when the coating is exposed to ultrasonic vibrations with an amplitude of 5 µm, it forms a solitary body-centered cubic (BCC) phase. The microhardness tripled compared to the substrate, and the most significant microhardness value was achieved at 5 µm of ultrasonic vibration. The friction coefficient was assessed at an ambient temperature, revealing that an ultrasonic amplitude yields the lowest friction coefficient, demonstrating the excellent wear resistance properties of the coating. The analysis of the 3D surface profile of the wear indicates that the use of ultrasonic aid with a 5 µm amplitude leads to reduced depth of scars, and the primary wear mechanism observed is abrasive and oxidative wear with fewer grooves and debris. In addition, XPS analysis revealed the presence of metal components in an oxidized condition, suggesting that the wear process is oxidative in nature. Integrating the R-UVALC setup into a resonance state can significantly enhance the efficiency of the laser cladding process in the laser cladding field.
共振超声振动辅助激光熔覆（R-UVALC）装置的设计涉及使用有限元分析（FEA）来模拟处于共振状态的超声换能器、变幅杆和工件。使用0、5、10和15 µm的各种超声振动幅度，在20 kHz的恒定频率下评估R-UVALC对AlCrFeMnNi高熵合金的影响。超声振动减少了气孔和裂纹，并增加了熔覆宽度、熔池润湿角和激光熔覆层的一致性。靠近基体表面的柱状拉长晶粒尺寸减小，并在5 µm振幅的超声振动作用下转变为更等轴状的晶粒。无超声振动的激光熔覆产生两种相：面心立方（FCC）和体心立方（BCC）。然而，当涂层受到5 µm振幅的超声振动时，它形成单一的体心立方（BCC）相。与基体相比，显微硬度增加了两倍，并且在5 µm的超声振动下获得了最高的显微硬度值。在环境温度下评估摩擦系数，结果表明超声振幅产生最低的摩擦系数，证明了涂层具有优异的耐磨性能。磨损的3D表面轮廓分析表明，使用5 µm振幅的超声辅助导致疤痕深度减小，观察到的主要磨损机制是磨料磨损和氧化磨损，沟槽和碎屑较少。此外，XPS分析揭示了氧化状态下金属成分的存在，表明磨损过程本质上是氧化的。将R-UVALC装置整合到共振状态可以显著提高激光熔覆领域中激光熔覆工艺的效率。
