In industries such as aerospace, petrochemistry and automobile, many parts of different machines are under environment which shows high temperature and high pressure, and have their proneness to wear and corrosion. Therefore, the wear resistibility and stability under high temperature need to be further improved. Nowadays, Laser cladding (LC) is widely used in machine parts repairing and functional coating due to its advantages such as lower dilution rate, small heat-affected zone and good metallurgical bonding between coating and substrate. In this paper, LC is introduced in detail from aspects of process simulation, monitoring and parameter optimization. At the same time, the paper gives a comprehensive review over LC material system as high entropy alloys (HEAs), amorphous alloy and single crystal alloy have been gradually showing their advantages over traditional metal materials in LC. In addition, the applications of LC in functional coatings and in maintenance of machine parts are also outlined. Also, the existing problems and the development trend of LC is discussed then.

Recent research and development status of laser cladding: A review

Additive manufacturing is an emerging technology that challenges traditional manufacturing methods. However, the corrosion behaviour of additively manufactured parts must be considered if additive techniques are to find widespread application. In this paper, we review relationships between the unique microstructures and the corresponding corrosion behaviour of several metallic alloys fabricated by selective laser melting, one of the most popular powder-bed additive technologies for metals and alloys. Common issues related to corrosion in selective laser melted parts, such as pores, molten pool boundaries, surface roughness and anisotropy, are discussed. Widely printed alloys, including Ti-based, Al-based and Fe-based alloys, are selected to illustrate these relationships, and the corrosion properties of alloys produced by selective laser melting are summarised and compared to their conventionally processed counterparts.

/pdf/corrosion-of-metallic-materials-fabricated-by-selective-447dz0n4d3.pdf

Corrosion of metallic materials fabricated by selective laser melting

A systematic research into the cladding of stellite 6 on stainless steel by pulsed Nd:YAG laser has been carried out. The effects of pulse energy, pulse frequency, powder mass flow rate and spot overlap on the clad layer height, dilution and heat-affected zone (HAZ) have been examined. It was found that both the clad height and penetration into the substrate increase with the pulse energy, spot overlap and pulse frequency, but the effects of these parameters on dilution are complex. The dilution reaches the lowest value (4%) at the incident energy of 18 and 25 J/ pulse, spot overlap of 89% and pulse frequency of 40 Hz. The powder mass flow rate of 22 g/min (for energy of 25 J/pulse and spot overlap of 83%) produces thick clad layer with low dilution but results in the formation of defects. The hardness of the clad layer decreases linearly with increasing dilution. No cracks have been found in single-track clad layers at a spot overlap of 89%, however, cracks occurred at lower spot overlap. These cracks were eliminated by the multi-track cladding when the track increment is less than 1/3 of the width of track, which is believed to be due to the remelting or heat treatment of the previous clad track by the subsequent track. The track bands in multi-track clad show coarser structure, higher element segregation and lower hardness.

Pulsed Nd:YAG laser cladding of stellite 6 on stainless steel

Effect of TiC content on the mechanical and corrosion properties of Inconel 718 alloy fabricated by a high-throughput dual-feed laser metal deposition system

The marine, aerospace, and power machinery industries show progression in the application of titanium alloy components due to their good properties. However, the alloy exhibits poor thermal stability, low hardness, and poor tribological properties; as a result, the use of Ti6Al4V in various industries is restricted. Consequently, a search for surface improvement of Ti6Al4V alloy arose with the intention of enhancing its endurance. The use of laser metal deposition method by integrating chemical barrier coatings is considered as advantageous; therefore, an investigation aimed at surface improvement of Ti6Al4V by incorporation of Ti-Co coatings developed. To fabricate the coatings, a 3-kW continuous wave ytterbium laser system (YLS) was used, and to control the movement of the cladding process, a KUKA robot was attached to the system. The microstructure, corrosion, and mechanical properties of the titanium alloy-cladded surfaces were studied at different laser process parameters. To analyze the microstructure of the cross section, optical and scanning electron microscopy were employed. A laser power of 750 W and scanning rate of 1.2 m/min were found to be the optimum process conditions for a 60Ti-40Co alloy. When comparing the mechanical properties of the alloy and bare substrate, the alloy exhibited a significant increase in terms of the hardness. It was found to have 719 HV as compared to 301 HV which is that of the substrate, this indicates to an increase of 58.14% in the hardness. Lower laser scanning rates result in a larger fraction of hard-intermetallic phases which in turn lead to coatings with enhanced hardness levels. Furthermore, the yield strength and tensile strength of the coatings increased to maxima of 2.30 and1.66 GPa, respectively in comparison to the substrate, due to the addition of Co. Additionally, the corrosion rates of all the coated specimens were reduced as a result of the oxide films formed on the laser-coated Ti6Al4V alloy samples.

Evaluation of microstructure, microhardness, and electrochemical properties of laser-deposited Ti-Co coatings on Ti-6Al-4V Alloy

Statistical analysis of the effect of welding parameters on the tensile strength of titanium reinforced mild steel joints using taguchi’s DoE

https://doi.org/10.1016/j.dib.2022.108181

Data related to influence of process parameters on the microstructure, structural and mechanical properties of additive manufactured titanium alloy composites

Experimental investigation on the effects of heat transfer using vacuum and fiberglass insulations over pipes for industrial application

In the quest of averting the drawbacks of alloys of titanium in advanced manufacturing, the laser metal deposition technique is used to fabricate suitable coatings with innovative microstructural evolution and unique surface properties in aggressive environment. The vital factor to be considered during direct laser metal deposition process is the simultaneous action of melting and fusion of the coating material to the base metal. The appropriate selection of laser processing parameter produced desirable result and properties. At scanning speed of 1.2 m/min, Al-10Sn-5Si coating has an ultimate hardness of 463.57 HV whilst at the scanning speed of 1.0 m/min the value has decreased to 398.36 HV (65.21 HV difference). Sample Al-10Sn-3Si also showed the same trend in increase hardness at 1.2 m/min. While Al-10Sn-1Si did not follow the trend of other two coatings. The model was developed to obtain insights on the behaviour of laser melted pools subjected to various process parameters. Simulation with 3D model with different values of various significant processing parameters such as laser power, scanning speed and powder feed rate influences the geometry and dynamics of the melt pool, and cooling rates.

Numerical Modelling, Microstructural Evolution and Characterization of Laser Cladded Al-Sn-Si Coatings on Ti-6Al-4V Alloy

Metal forming is one of the conventional manufacturing processes of immense relevance till date even though modern manufacturing processes have evolved over the years. It is a known fact that material tends to return or spring back to its original form during forming or bending. The phenomena have been well managed through its application in various manufacturing processes by compensating for the spring back through overbending and bottoming. Overbending is bending the material beyond the desired shape to allow the material to spring back to the expected shape. Bottoming, on the other hand, is a process of undergoing plastic deformation at the point of bending. This study reports on the finite element analysis of the effect of bottoming on the material property during the sheet forming process with the aim of optimising the process. The result of the analysis revealed that the generated plastic strains are in the order between 1.750e00-1 at the peak of the bending and 3.604e00-2, which was at the early stage of the bending.

Olawale S. Fatoba

Papers

Statistical analysis of the effect of welding parameters on the tensile strength of titanium reinforced mild steel joints using taguchi’s DoE

Data related to influence of process parameters on the microstructure, structural and mechanical properties of additive manufactured titanium alloy composites

Experimental investigation on the effects of heat transfer using vacuum and fiberglass insulations over pipes for industrial application

Numerical Modelling, Microstructural Evolution and Characterization of Laser Cladded Al-Sn-Si Coatings on Ti-6Al-4V Alloy

Effect of Bottoming on Material Property during Sheet Forming Process through Finite Element Method