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激光熔覆Ni35A+TiC复合材料熔覆形貌 及成形效率影响研究

Study on the effect of laser cladding Ni35A + TiC composite cladding morphology and forming efficiency

  • 摘要: 为了揭示激光熔覆工艺参数及TiC粉末比例对复合材料熔覆形貌与成形效率的影响关系,改善熔覆形貌包括表面质量与基材熔化深度,提高复合材料熔覆成形效率,采用响应面法中心复合设计模块分析了激光功率、扫描速度、气流量及TiC粉末比例对复合材料熔覆形貌的影响规律,建立了工艺参数及TiC粉末比例与复合材料熔覆效率、基材熔化深度之间的数学模型,通过方差分析证明了模型的合理性.结果显示,气流量对复合材料熔覆形貌影响并不显著,熔覆形貌随着激光功率增大、扫描速度减小及TiC粉末比例减少而得到明显改善;扫描速度及TiC粉末配比对熔覆效率影响最为显著,合理减小TiC粉末配比及增加扫描速度可以有效提高熔覆效率;激光功率对基材熔化深度影响最显著且呈二次正相关关系,其余参数均呈负线性相关关系;分析发现不同材料的熔覆能量需求是导致不同材料成分比例复合材料熔覆效率及形貌差异的最主要原因.以熔覆效率最大及基材熔化深度最小为优化目标,对比预测值与实验值,得到熔覆效率及基材熔化深度的误差率分别为3.450%、5.386%.该研究为提高复合材料熔覆形貌及熔覆效率的预测与控制提供了理论依据.

     

    Abstract: In order to investigate the influence of laser cladding process parameters and TiC powder ratio on the cladding morphology and forming efficiency of composite materials ,improve the cladding morphology in terms of surface quality and substrate melting depth, and improve the forming efficiency of composite materials, the central composite design module of the response surface methodology(RSM) was adopted to analyze the effects of laser power, scanning speed, gas flow and TiC powder ratio on the morphology of composite claddings. A mathematical model was established between process parameters and TiC powder ratio, and composite cladding efficiency and substrate melting depth. The accuracy of the model was verified by variance analysis. Results show that, the effect of gas flow on the morphology of composite claddings is not significant. The cladding morphology is remarkably improved by increasing laser power, decreasing scanning speed and reducing TiC powder ratio. The scanning speed and TiC powder ratio have the most remarkable effects on the cladding efficiency. Therefore, reducing the TiC powder ratio and increasing the scanning speed appropriately could improve the cladding efficiency. Laser power has the most significant influence on the melting depth of the substrate and shows a secondary positive correlation, and the remaining parameters show a negative linear correlation. The analysis reveals that different materials’ requirement for cladding energy is the most important cause of the difference in the cladding efficiency and the morphology of composite materials with different compositions. With the maximum cladding efficiency and the minimum melting depth of the substrate as the goal of optimization, a comparison was made between the predicted and test values and found that the error rate of the cladding efficiency and that of the melting depth of the substrate were 3.450% and 5.386% respectively. This research provides a theoretical guidance for composite materials in improving the cladding morphology, and for predicting and controlling the cladding efficiency.

     

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