激光熔覆原位合成WC单道成形控制方法

采用响应面法中心复合设计建立激光功率、扫描速度、气流量、WC粉末配比与熔覆层宽度、高度、横截面积之间的数学模型,通过方差分析和模型验证,验证了数学模型的准确性。熔覆层的宽度与激光功率成正比,与扫描速度、气流量、粉末配比成反比;熔覆层的高度和横截面积与激光功率成正比,与扫描速度、粉末配比成反比。最后以熔覆层宽度和横截面积最大,高度最小为目标优化工艺参数,通过试验验证获得熔覆层宽度、高度和横截面积预测值和实际值误差分别为9.439%、5.153%、4.835%,平均误差率低于6.5%,进一步验证了所建立模型的准确性。研究结果为WC激光熔覆原位合成成形质量的预测、控制及工艺参数优化提供理论参考依据。

Single-track forming control method for in-situ synthesis of WC by laser cladding

Central composite design of response surface method was adopted to establish a mathematical model between the laser power, scanning speed, gas flow rate, WC powder ratio and the width, height, and cross-sectional area of the clad layer. The validity of the mathematical model was established by the analysis of variance and model verification. The clad width is proportional to the laser power, but inversely proportional to the scanning speed, gas flow rate and powder ratio. The clad height and cross-sectional area is proportinal to the laser power, but inversely proportional to the rising of scanning speed and powder ratio. Finally, the process parameters were optimized with the target of maximizing the clad width and cross-sectional area and minimizing the height. An experimental validation indicates that the error rates between the predicted and actual values for the clad width, height and cross-sectional area are 9.439%, 5.153% and 4.835%, respectively. The average error rate is less than 6.5%, further verifying the accuracy of the established model. The research results provide a theoretical reference for the prediction, control and optimization of process parameters of the forming quality of in-situ synthesis WC by laser cladding.