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Macro–micro residual stress prediction and hot crack formation mechanism during laser melt injection processing of ZrO2 particles into Ti6Al4V substrate

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Abstract

Laser melt injection (LMI) is a promising technology to produce ceramic particles reinforced metal matrix composites (MMCs) to achieve surface modification and performance upgrading. In this paper, the LMI process was conducted on a Ti6Al4V substrate with ZrO2 particles (ZrO2p) to produce a functionally graded material. Subsequently, a novel finite element model, at both macro and micro scales, was proposed to calculate the thermal–mechanical characteristics during the LMI process to expound on the crack formation mechanism. The differences in experiments, including track dimensions, particle distribution, and crack morphology of the MMC layer, were analyzed, corresponding to varied laser power and scanning velocity. The three-dimensional macro-simulated results showed alternating tensile-compressive residual stresses spread over the heat-affected zone. Besides, the most significant longitudinal tensile stress, the peak values exceeding the yield strength of Ti6Al4V, was distributed on the MMC top surface, leading to cracks. The two-dimensional micro-scale models revealed the residual stress distributed remarkably uniformly in the ZrO2 particles, and the stress values were more significant than those of the Ti6Al4V substrate. Furthermore, there were stress concentration points on the surfaces of ZrO2p, which were the sources of micro-fissure. At the same time, the gaps caused between the Ti6Al4V matrix and the ZrO2p surface also provided the conditions for the formation of microcracks. More conspicuous cracks would be generated after lots of microcracks were gathered.

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source model for LMI simulation

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Acknowledgements

The authors gratefully acknowledged projects funded by China Postdoctoral Science Foundation (No. 2020M671479) and Priority Academic Program Development of Jiangsu Higher Education Institutions (PAPD).

Funding

This work was supported by the China Postdoctoral Science Foundation (No. 2020M671479) and Priority Academic Program Development of Jiangsu Higher Education Institutions (PAPD).

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Authors and Affiliations

  1. Shanghai Spaceflight Precision Machinery Institute, Shanghai, 201600, China

    Zipeng Ouyang, Qunlin Cheng & Wenqi Chen

  2. College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 211106, China

    Hongxi Jin & Yanhong Wei

  3. MIIT Key Laboratory of Pattern Analysis and Machine Intelligence, College of Computer Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 211106, China

    Jicheng Chen

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  1. Zipeng Ouyang
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  4. Wenqi Chen
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  5. Yanhong Wei
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Correspondence to Jicheng Chen.

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Ouyang, Z., Jin, H., Cheng, Q. et al. Macro–micro residual stress prediction and hot crack formation mechanism during laser melt injection processing of ZrO2 particles into Ti6Al4V substrate. Int J Adv Manuf Technol 121, 3637–3651 (2022). https://doi.org/10.1007/s00170-022-09561-x

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