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Numerical Optimization and Performance Study of Ni-Based Coatings on Gray Cast Iron Surface by High-Speed Laser Cladding Based on Orthogonal Test

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Abstract

To improve the cladding quality of Ni-based powder on gray cast iron by high-speed laser cladding, ANSYS was used to construct the cladding model. The effects of laser power P, scanning rate v, and spot diameter r on the cladding quality were explored in terms of substrate surface temperature, temperature gradient G/solidification rate R, and heat-affected zone (HAZ) by the three-factor and three-level orthogonal test. The parameters that significantly affect the factors v and r were determined. Based on simulation tests, the effect of P on the microstructure, hardness and wear resistance of the molten layer was investigated by using scanning electron microscopy (SEM), hardness tester, friction wear machine and ultra-depth of field. The results showed that the microstructure of the cladding layer became sparse and coarse with increasing P, and the cross-sectional hardness and surface hardness didn’t change much. Compared to 2000 W, the wear quality loss of 1600 and 2400 W is improved by 24.8, 40.4%. The best wear resistance was achieved for 2000 W. The wear resistance and bond strength of Ni-based coating are optimal when v = 3 mm, r = 30 mm/s, and P = 2000 W.

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Data Availability

The datasets generated during and/or analyzed during the current study are available from the corresponding authors upon reasonable request.

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Funding

This research was supported financially by the National Natural Science Foundation of China (No. 52275358) and University Doctoral Research Initiation Grant (No. 2023085).

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Authors and Affiliations

  1. School of Mechanical Engineering, Taiyuan University of Science and Technology, Taiyuan, 030024, China

    Huan Li, Rui Wang, Runze Wei, Chunjiang Zhao, Changyao Ouyang, Rui Deng & Qiaofeng Bai

  2. School of Mechanical and Equipment Engineering, Hebei University of Engineering, Handan, 056038, China

    Rui Wang

  3. Ertuoqianqi Great Wall No. 5 Mining Co., Ltd., Ertokqianqi, 016200, China

    Muhua Mao

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  1. Huan Li
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by RW, MM, CO, RW and CZ. The first draft of the manuscript was written by HL and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Chunjiang Zhao.

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Li, H., Mao, M., Wang, R. et al. Numerical Optimization and Performance Study of Ni-Based Coatings on Gray Cast Iron Surface by High-Speed Laser Cladding Based on Orthogonal Test. J. of Materi Eng and Perform (2024). https://doi.org/10.1007/s11665-024-09487-3

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