Laser surface alloying of case hardening steel with tungsten carbide and carbon

Abstract

The laser surface alloying process was used to introduce two different alloying materials, tungsten carbide (WC/Co) and carbon, into the molten surface of a case hardening steel (16MnCrS5), to improve its hardness and wear resistance. The chemical composition and the resulting microstructure in the alloyed layers were of particular interest in this investigation, because the strengthening mechanism was strongly dependent upon the type and amount of the alloy material. For laser alloying with carbon the increase in hardness and wear resistance was based on the martensitic transformation in the composition range concerned. For alloying with tungsten carbide it was necessary to consider two different strengthening mechanisms, namely, martensitic transformation and precipitation of carbides. In both cases the grain refinement in the laser affected zone had an additional effect. Resistance to dry abrasive sliding wear was measured using a conventional pin-on-disc wear testing machine. For both alloy materials the wear rate was substantially lower than that of a substrate that had been laser remelted without alloying additions.

MST/1556     

Laser surface alloying of medium carbon steel with SiC(P)

Laser surface alloying (LSA) is increasingly recognised as a powerful surface modification tool to enhance the wear and corrosion resistance of engineering components. The present work deals with laser alloying of medium carbon steel with silicon carbide using a high-power CO₂ laser. A processing regime, identifying an appropriate laser power-scan speed combination for achieving defect-free alloyed layers, has been established during the study. The influence of repetitive scans on the alloyed layer properties was also subsequently investigated in a comprehensive manner. Repetitive scanning was found to affect substantially the laser-alloyed zone (LAZ) and heat-affected zone dimensions, as well as the phase constitution of the laser-alloyed layers. The microstructure in the LSA layers was also observed to vary significantly with the number of scans, besides changing quite distinctly with depth in the LAZ. Tribological tests revealed considerable improvement in abrasive wear performance by laser surface alloying, and the results also emphasise the need to control the number of repetitive scans to achieve optimum performance.     

M17Ni基合金激光表面Y合金改性层的显微组织

采用 Cr+Al-Y 合金粉末,通过激光表面熔化,对 Ni 基高温合金 M17表面改性处理,观察改性层的显微组织、相组成、成分分布,讨论激光加工条件的影响。活性元素 Y 总是伴随元素Al 存在,并在表层及其内部发生局部分离偏聚。     

20Cr_（2）Ni_（4）W钢钴粉涂层激光合金化的试验研究

本文采用２ｋＷＣＯ_２激光器对２０Ｃｒ_（２）Ｎｉ_（４）Ｗ钢进行了激光表面钴合金化的试验研究。用光学显微镜、扫描电镜、电子探针、Ｘ射线衍射、透射电镜、显微硬度计等手段分析了合金化区域的成分、组织和性能。结果表明，激光表面钴合金化可获得含钴均匀的合金化层，合金化层的高温硬度和热疲劳性能均有提高，在热作工具钢表面性能优化领域有着良好的应用前景。     

Rapidly Solidified Microstructure in Laser Alloyed Ni-Al Layer by TEM,STEM z-contrast and HRTEM Techniques

In the present study, laser alloying of electroless Nie P coating on aluminum substrate was conducted using Nd：YAG pulsed laser under the condition of 5.36 109W/m2 in power density and 3.0 mm/s in scanning speed. The rapidly solidified microstructure in the alloyed layer was studied. The results showed that the alloying element distributed in the alloyed layer is inhomogeneous. The dendrite containing relatively high Ni was identified as Al3Ni phase and the areas between the dendrites are rich in Al content. Featureless with cell structure in Al-rich areas was firstly displayed by z-contrast image. Amorphous structure was revealed to exist in Al-rich areas.     

热轧辊等离子束表面合金化层的显微组织及性能

传统的热处理不能很好地解决热轧辊在服役期内的失效问题。采用等离子柬表面合金化技术对热轧辊表面进行了强化,利用SEM,X射线衍射仪和显微硬度计对合金化层的显微组织、成分、物相和截面显微硬度分布进行了分析。结果表明：合金化层由合金化区、热影响区组成,合金化区域表面较平整,与热影响区以及热影响区与基体之间都形成了良好的冶金结...     

Microhardness and Microstructure Studies on Laser Surface Alloyed Aluminum Alloy with Ni-Cr

Aluminum alloy LM13 was surface alloyed with Ni and Cr of different compositions (in wt.%) at various laser powers (1 kW, 1.5 kW, and 2 kW) using CW CO₂ laser. Microhardness and microstructure of alloyed regions were examined.

The study shows that surface alloying is achieved when the laser power is sufficiently high (1.5 kW). Microhardness increases appreciably when the Cr concentration is increased in the Ni-Cr composition. However, in the alloyed region, large variations in microhardness are observed with depth below the surface of the material. Microstructure exhibits needle structure when Ni-concentration is high and undergoes a phase transformation when Cr-concentration is increased. XRD analysis in the alloyed samples shows formation of intermetallic compounds.     

In situ formation of TiC particulate composite layer on cast iron by laser alloying of thermal sprayed titanium coating

Commercial flake graphite cast iron substrate was coated with titanium powder by low pressure plasma spraying and was irradiated with a CO₂ laser to produce the wear resistant composite layer. The macro and microstructural changes of an alloyed layer with the traveling speeds of laser beam, the precipitate morphology of TiC particulate and the hardness profile of the alloyed layer was examined. From the results, it was possible to composite TiC particulate on the surface layer by direct reaction between carbon existed in the cast iron matrix and titanium with thermal sprayed coating by remelting and alloying them using laser irradiation. The cooling rate of the laser remelted cast iron substrate without a titanium coating was about 1 × 10⁴ K/s to 1 × 10⁵ K/s in the order under the condition of this study. The microstructure of the alloyed layer consisted of three zones; the TiC particulate precipitate zone (MHV 400–500), the mixed zone of TiC particulate + ledeburite (MHV 650–900) and the ledeburite zone (MHV 500–700). TiC particulates were precipitated as a typical dendritic morphology. The secondary TiC dendrite arms were grown to a polygonized shape and were necking. Then the separated arms became cubic crystal of TiC at the slowly solidified zone. In the rapidly solidified zone near the fusion boundary, however the fine granular TiC particulates were grouped like grapes.     

钛合金激光表面处理研究

本文采用5KWTEACO_2激光器,对 Ti—6Al—4V 钛合金进行表面合金化处理,实验结果表明,经激光辐照后,材料表层及次表层组织结构产生变化,与基体组织大不相同,其硬度有很大提高,由 Hv250提高到 Hv800～900。磨损试验表明,经激光处理的试件,其耐磨性提高2～3倍。扫描电镜分析表明:处理区域由精细枝晶区,等轴细晶区和马氏体区组成,表层硬度的提高及耐磨性的改善与表层组织形态、晶粒细化及硬质点的弥散分布有关。     

Laser Surface Alloying of (Pre-placed) SiC and Ni-SiC Coating on Commercially Pure Titanium

Results of laser alloying of 100% SiC and 50% Ni + 50% SiC on commercially pure titanium were presented in this investigation. The high hardness Hv800-1200 obtained at 100% SiC and 50% Ni + 50% SiC alloying conditions were due to the presence of various intermetallic phases such as TiC, TiSi, Ti₅Si₃ and NiTi₂. These intermetallic phases present in the laser alloyed surface were validated by EDXRD analysis and the diffusion of Ni, Si, C in titanium responsible for these phase formations was identified by SIMS study. The alloyed layer microstructure consists of dendrites and its density level depends on laser processing conditions. At low level power density the alloyed layer depth was about 0.5 mm with a constant hardness level, whereas at higher level powerdensity the depth of alloyed layer touched a maximum of 1.6 mm with large fluctuation in hardness.     

Development of wear resistant composite surface on mild steel by laser surface alloying with silicon and reactive melting

The present study concerns laser surface alloying with silicon of mild steel substrate using a high-power continuous wave CO₂ laser with an objective to improve wear resistance. The effect of surface remelting using nitrogen as shrouding environment (with and without graphite coating) on microhardness and wear resistance has also been evaluated. Laser surface alloying leads to formation of a defect free microstructure consisting of iron silicides in laser surface alloyed mild steel with silicon and a combination of silicides and nitrides when remelted in nitrogen. Carbon deposition prior to remelting leads to presence of a few martensite in the microstructure. A significant improvement in microhardness is achieved by laser surface alloying and remelting to a maximum of 800 VHN when silicon alloyed surface is melted using nitrogen shroud with carbon coating. A detailed wear study (against diamond) showed that a significant improvement in wear resistance is obtained with a maximum improvement when remelted in nitrogen atmosphere followed by carbon coating.     

Two step coating of a hypereutectic PM Al-Si alloy

The aim of the present work was to combine the high strength of Al-Si alloys produced via Rapid Solidification (RS) and Spray Forming (SF) with a wear resistant surface coating, designed for high temperature use. The surface coating, composed mainly of nickel and chromium, was applied in a two step process: plasma spray followed by laser surface alloying using a diode laser. The microstructure and hardness of the surface coating were analysed. In the Al-Si alloys produced via Rapid Solidification, gas bubble formation was observed during the laser alloying process. In the Spray Formed alloys, globules of the coating material and a needle-like microstructure formed, in detriment to the mechanical properties of the alloyed layer.     

An investigation on the laser surface alloying of copper on iron

Laser surface alloying of iron substrate with copper under different processing conditions has been systematically studied. The microstructural analysis reveals a predominantly cellular microstructure with copper wetting the cell boundaries. Globular distribution of copper at higher laser scanning speeds can be observed occasionally indicating the system under these conditions to be near the metastable miscibility gap. The concentration of copper in the pool is related to the laser scanning speed. In all cases a banded morphology indicating unsteady growth towards the bottom of the alloyed zone is observed. The hardness of the alloyed zone is significantly higher and is attributed to work hardening due to differential thermal contraction of the two phases in the alloyed zone.     

Influence of laser-mechanical treatment on surface topography,erosive wear and contact stiffness

This paper presents the study of surface topography, erosive wear and contact stiffness after the new hybrid method has been applied for the modification of steel surface layer. A combination of laser alloying and the burnishing process, both performed in laser set up, was proposed in order to reduce surface roughness being formed during laser treatment, and to improve contact stiffness. The experiments were conducted on stainless steel, alloyed with Stellite 6, and simultaneously burnished in hot and cold conditions in one operation. The alloying process was performed with continuous laser CO₂ at different parameters. The influence of hybrid treatment parameters on surface topography was examined. This hybrid treatment reconstructed the surface topography and caused an increase in surface smoothness compared to laser alloying. More than a threefold decrease in the average level of roughness, S_a, due to the burnishing process was stated. A good correlation between the parameters of hybrid treatment and roughness was demonstrated. The study shows that laser-mechanical treatment improves erosive wear and contact stiffness compared to laser alloyed and thermal sprayed Stellite 6 layers.     

Microstructure of mechanically alloyed Al-In alloys

Mechanical alloying (MA) starting from elemental powder mixtures was performed on immiscible Al-10, 30 and 50 at % In alloys. Al and In were finely mixed with increasing MA time and the crystal size of each element became up to 40 nm after MA for 1152 ks. With refinement of the structure, the hardness increased up to 120 H _v in Al-10 at % In alloy, a value larger than that obtained from the rule of mixtures. The melting temperature of In was recognized, by thermal analyses, to fall by about 3 K for mechanically alloyed Al-In alloy, showing the possibility of forming f.c.t In supersaturated solid solution. A new endothermal peak around 420 K, which corresponded with the melting temperature of metastable f.c.c. In, was recognized for mechanically alloyed Al-50 at % In alloy.     

Influence of laser surface alloying with chromium and nickel on corrosion resistance of type 304L stainless steel

Abstract

The influence of laser surface alloying (LSA) with Cr and Cr + Ni on the corrosion behaviour of type 304L stainless steel (SS) was investigated using potentiodynamic polarisation and electrochemical impedance spectroscopy (EIS) in chloride (0·5M NaCl) and acidic (1 N H₂SO₄) media. Surface alloying was carried out by laser cladding type 304L SS substrate with premixed powders of AISI type 316L SS and the desired alloying elements. The results indicated that Cr surface alloyed specimen exhibited a duplex (γ + α) microstructure with Cr content of ～24 wt-%, whereas Cr + Ni surface alloyed specimen was associated with austenitic microstructure with Cr and Ni contents of ～22 wt-% each. The potentiodynamic polarisation results in chloride solution indicated that LSA with Cr + Ni considerably enhanced the pitting corrosion resistance compared with LSA with Cr alone. In acidic media, such beneficial effects were not observed. Electrochemical impedance spectroscopy results showed an increase in semicircle arc for both chloride and acidic media for both Cr and Cr + Ni clad samples indicating improvement in the oxide film stability compared with untreated specimen. The polarisation resistance was higher and capacitance values of the laser clad specimen were lower than those in the untreated specimen. The microstructural changes and compositional variations produced by LSA are correlated to the corrosion behaviour.     

Nb掺杂对Ti-Al合金化层抗高温氧化性能的影响

为提高钛合金TC4的抗高温氧化性能,采用激光表面合金化技术在钛合金表面制备不同Nb掺杂量的Ti-Al合金化层。采用X射线衍射仪(XRD)、扫描电子显微镜(SEM)、能谱仪(EDS)、箱式电阻炉等对合金化层的组织结构和高温氧化行为进行分析测试。结果表明,合金化层主要组成物相为TiAl以及少量的Ti_3Al相。Nb主要以置换溶质原子的形式固溶于合金化层中。合金化层组织均匀,与基体呈典型的冶金结合,在不含Nb的Ti-Al合金化层中发现大量的表层裂纹及少量的贯穿性裂纹,而在Nb掺杂的合金化层中未发现明显的宏观裂纹。合金化层在800℃保温1000h的氧化增重显著低于基体,表现出优异的抗高温氧化性能。相比而言,随着Al含量和Nb掺杂量的提高,合金化层的抗高温氧化能力也随之提高。Nb掺杂提高Ti-Al合金化层抗高温氧化性能的作用机理包括减少TiO_2中的空位缺陷、细化氧化物颗粒及促进Al_2O_3的形成。     

Non-equilibrium solidification by laser surface alloying of molybdenum with nickel: Structure and properties of alloyed layers

Surface alloying was carried out on molybdenum using continuous wave Nd : YAG and CO₂ lasers. The alloying element (nickel) was deposited on the molybdenum surface by plasma spraying. Microstructure evolution and phase identification was investigated by means of optical and scanning microscopy and X-ray microanalysis. Layers with an average content of about 33% at. of nickel were obtained. Rapid solidification with fine scale microstructures and non-equilibrium nickel rich phases was reported. Molybdenum oxides with a suggested composition of the MoO₂ were also identified. In addition the results of investigations of the alloyed layer microhardness and the layer resistance to erosion in an electric arc have been presented.     

LASER SURFACE TREATMENTS FOR PROMOTING CORROSION RESISTANCE OF A CARBON STEEL

The effect of laser treatment and laser alloying on corrosion resistance of 1045 steel has been studied. Various ways of surface alloying have been investigated by using continuous CO₂ laser beam: i) irradiation of chromium painted surfaces; ii) irradiation of Ni and Cr-electroplated surfaces; iii) direct injection of Ni and Cr powders into the melt pool. A high and uniform level of alloying in the surface layer can be achieved in the cases of electroplated surfaces and direct powder injection. It requires, however, an appropriate choice of irradiation conditions (such as beam power, beam traverse speed, beam defocusing and degree of overlapping) that provide remelted layer of a limited and fairly uniform thickness. It has been found that in order to achieve corrosion behavior of laser treated surfaces similar to that of austenite type 304 stainless steel chromium and nickel contents in the alloyed layer are to be higher than those of 304 steel.     

45钢激光合金化后的组织结构及性能

对45钢激光合金化处理可改善其组织结构及性能。研究了45钢不同工艺条件(功率、扫描速度)下激光处理后的组织结构、成分、显微硬度以及耐腐蚀性能。结果表明:45钢合金化后从表层到基体的区域分为合金化区、过渡区和热影响区,其中合金化区由树枝晶和胞状晶组成;合金化区的显微硬度相对于基体有明显提高,且随扫描速度以及功率的增大,合金化区的硬度增大;45钢合金化后耐腐蚀性能得到了较大的提升。