Skip to main content
SpringerLink
Log in

Numerical simulation research on multifield coupling evolution mechanism of IN625 laser cladding on nodular cast iron

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

This article has been updated

Abstract

Nodular cast iron has the strength and toughness which are close to steel and is widely used in industrial fields. The repair and modification of nodular cast iron based on laser cladding can effectively improve the service life, corrosion resistance, and wear resistance of parts. However, nodular cast iron cladding is prone to cracks and hole defects, severely limiting the promotion and application of this technology. The evolution mechanism of multi-field coupling in the spheroidal graphite cast iron laser cladding is the key to quantitatively reveal the improvement of cladding quality. In this paper, moving Gaussian heat source, the influence of temperature change on material physical parameters, the Marangoni effect of molten pool surface tension, and buoyancy on the molten metal flow were considered. A multifield coupling three-dimensional numerical model of IN625 powder laser cladding on nodular cast iron by disk lasers was established. The calculation reveals the transient evolution law of the cladding temperature field, flow field, and plastic stress field. The microstructure morphologies of the cladding layer were observed by Zeiss sigma HD field emission SEM to verify the effectiveness of the model. The results show that the substrate heat input and heat loss reached equilibrium at 0.8s, and the highest temperature reached 1979.7K. There was apparent Marangoni flow in the molten pool, resulting in a small flow velocity in the center and large edges, and the maximum flow velocity was 0.203m/s. When the molten pool was air-cooled to ambient temperature in 1000s, the maximum residual stress was 429MPa. The micromorphology from the bottom to the top of the molten pool is planar crystals, cell crystals, columnar crystals, and equiaxed crystals, which are consistent with the numerical calculation results.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig.18
Fig. 19
Fig. 20
Fig. 21

Similar content being viewed by others

Data availability

The authors confirm that the data supporting the findings of this study are available within the article.

Change history

  • 14 March 2022

    Springer Nature’s version of this paper was updated to remove the blank page found in the PDF version and the placement of figures have been rearranged.

References

  1. Takemoto Y, Mizumoto M, Kinno K (2020) Internal porosity defects in ductile cast irons. Int J Metalcast 1–14. https://doi.org/10.1007/s40962-020-00527-x

  2. Endo M, Yanase K (2014) Effects of small defects, matrix structures and loading conditions on the fatigue strength of ductile cast irons. Theor Appl Fract Mec 69:34–43. https://doi.org/10.1016/j.tafmec.2013.12.005

    Article  Google Scholar 

  3. Gu DD, Meiners W, Wissenbach K, Poprawe R (2013) Laser additive manufacturing of metallic components: materials, processes and mechanisms. Int Mater Rev 57(3):133–164. https://doi.org/10.1179/1743280411Y.0000000014

    Article  Google Scholar 

  4. Lambarri J, Leunda J, Navas VG, Soriano C, Sanz C (2013) Microstructural and tensile characterization of Inconel 718 laser coatings for aeronautic components. Opt Laser Eng 51(7):813–821. https://doi.org/10.1016/j.optlaseng.2013.01.011

    Article  Google Scholar 

  5. Gnanamuthu D S (1976) High temperature coatings by surface melting: US, 3952180

  6. Zhao G, Cho C, Kim J-D (2003) Application of 3-D finite element method using Lagrangian formulation to dilution control in laser cladding process. Int J Mech Sci 45(5):777–796. https://doi.org/10.1016/S0020-7403(03)00140-1

    Article  MATH  Google Scholar 

  7. Mirzade FK, Khomenko MD, Niziev VG (2016) Numerical simulation of solute evolution during laser cladding with nickel superalloy powder injection. Opt Quant Electron 48(11):513. https://doi.org/10.1007/s11082-016-0779-4

    Article  Google Scholar 

  8. Cheng YH, Cui R, Wang HZ, Han ZT (2017) Effect of processing parameters of laser on microstructure and properties of cladding 42CrMo steel. Int J Adv Manuf  Tech. https://doi.org/10.1007/s00170-017-0920-y

  9. Li R, Qiu Y, Zheng Q, Liu B, Chen S, Tian Y (2018) Finite element simulation of temperature and stress field for laser cladded nickel-based amorphous composite coatings. Coatings 8(10). https://doi.org/10.3390/coatings8100336

  10. Khamidullin B A, Tsivilskiy I V, Gorunov A I, Gilmutdinov A K (2019) Modeling of the effect of powder parameters on laser cladding using coaxial nozzle. Surf Coat Technol 364. https://doi.org/10.1016/j.surfcoat.2018.12.002

  11. Luo K Y, Xu X, Zhao Z, Zhao S S, Cheng Z G, Lu J Z (2019) Microstructural evolution and characteristics of bonding zone in multilayer laser cladding of Fe-based coating. J Mater Process Technol 263:50-58https://doi.org/10.1016/j.jmatprotec.2018.08.005

  12. Jg A, Cw A, Yh B, Xx A, Lg B (2020) Numerical simulation and experimental investigation on three-dimensional modelling of single-track geometry and temperature evolution by laser cladding. Opt Laser Technol 129. https://doi.org/10.1016/j.optlastec.2020.106287

  13. He X, Fuerschbach PW, Debroy T (2003) Heat transfer and fluid flow during laser spot welding of 304 stainless steel. J Phys D Appl Phys 36(12):1388. https://doi.org/10.1088/0022-3727/36/12/306

    Article  Google Scholar 

  14. Li C, Yu Z, Gao J, Zhao J, Han X (2018) Numerical simulation and experimental study of cladding Fe60 on an ASTM 1045 substrate by laser cladding. Surf Coat Technol 357:965–977. https://doi.org/10.1016/j.surfcoat.2018.10.099

    Article  Google Scholar 

  15. Kubiak M, Piekarska W, Stano S (2015) Modelling of laser beam heat source based on experimental research of Yb:YAG laser power distribution. Int J Heat Mass Transf 83:679–689. https://doi.org/10.1016/j.ijheatmasstransfer.2014.12.052

    Article  Google Scholar 

  16. Guo Q, Zhao C, Qu M, Xiong L, Hojjatzadeh SMH, Escano LI, Parab ND, Fezzaa K, Sun T, Chen L (2019) In-situ full-field mapping of melt flow dynamics in laser metal additive manufacturing. Addit Manuf 31. https://doi.org/10.1016/j.addma.2019.100939

  17. Wirth F, Wegener K (2018) A physical modeling and predictive simulation of the laser cladding process. Addit Manuf 22:307–319. https://doi.org/10.1016/j.addma.2018.05.017

    Article  Google Scholar 

  18. Zhang F, Zhang C, Chen SL, Zhu J, Cao WS, Kattner UR (2014) An understanding of high entropy alloys from phase diagram calculations. Calphad 45:1–10. https://doi.org/10.1016/j.calphad.2013.10.006

    Article  Google Scholar 

  19. Zhang C, Miao J, Chen S, Zhang F, Luo A (2019) CALPHAD-based modeling and experimental validation of microstructural evolution and microsegregation in magnesium alloys during solidification. J Phase Equilib Diff 40(4):495–507. https://doi.org/10.1007/s11669-019-00732-0

    Article  Google Scholar 

  20. Liu H, Li M, Qin X, Huang S, Hong F (2019) Numerical simulation and experimental analysis of wide-beam laser cladding. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-018-2740-0

  21. Jiang Y, Cheng Y, Zhang X, Yang J, Yang X, Cheng Z (2019) Simulation and experimental investigations on the effect of Marangoni convection on thermal field during laser cladding process. Optik 203. https://doi.org/10.1016/j.ijleo.2019.164044

  22. Song B, Yu T, Jiang X, Xi W (2019) Numerical model of transient convection pattern and forming mechanism of molten pool in laser cladding. Numer Heat Transf A Appl 75(12):855–873. https://doi.org/10.1080/10407782.2019.1608777

    Article  Google Scholar 

  23. Wang ZJ, Dong SY, Xu BS, Xia W (2010) Effect of laser cladding processing parameters on metal forming efficiency and geometry. Infrared Laser Eng 39(02):315–319. https://doi.org/10.1155/2010/293410

    Article  Google Scholar 

  24. Mingzhong HAO (2012) The optimization of laser cladding process parameters and adaptive finite element analysis. Dalian University of Technology, Dalian, pp 19–21

    Google Scholar 

  25. Tao YF, Jun LI, Ying-Hao L, Lie-Feng HU (2017) Residual stress distribution in different depths of TiNi/Ti_2Ni-based laser clad coating prepared at different environmental temperatures. Trans Nonferrous Met Soc 027(009):2043–2054

    Article  Google Scholar 

  26. Gan Z, Gang Y, He X, Li S (2017) Numerical simulation of thermal behavior and multicomponent mass transfer in direct laser deposition of Co-base alloy on steel. Int J Heat Mass Trans 104(3):28–38. https://doi.org/10.1016/j.ijheatmasstransfer.2016.08.049

    Article  Google Scholar 

Download references

Funding

This work was supported by the Innovation Team Construction Project of University of Science and Technology Liaoning (601009830), Liaoning Provincial Natural Science Foundation (2019ZD0277), and University Innovation Talent Support Plan of Liaoning Province (20201020).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering and Automation, University of Science and Technology Liaoning, Anshan, 114051, China

    Chang Li, Yan Xu, Tenghui Jia, Junjia Zhao & Xing Han

Authors
  1. Chang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yan Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tenghui Jia
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Junjia Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Xing Han
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Li Chang wrote the manuscript and is responsible for the experimental work. Xu Yan contributed to making the numerical simulation of the article. Jia Tenghui, Zhao Junjia, and Han Xing contributed to data extraction and format correction of the article. All the authors read and approved the final manuscript.

Corresponding author

Correspondence to Chang Li.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

All authors consented to the publication.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Li Chang and Xu Yan are co-first authors of the article

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, C., Xu, Y., Jia, T. et al. Numerical simulation research on multifield coupling evolution mechanism of IN625 laser cladding on nodular cast iron. Int J Adv Manuf Technol 119, 5647–5669 (2022). https://doi.org/10.1007/s00170-021-08249-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-08249-y

Keywords

Search

Navigation