A solid-state cold-spray technique was employed for depositing the copper-coated graphite reinforced copper-based composite coatings on aluminum alloy 6061 T6 substrate under different process parameters. The optimum process parameters of the cold-sprayed coatings were predicted in terms of surface roughness, thickness and adhesion. The surface roughness was measured using a 3D profilometer, the thickness and element constitution were detected by an optical microscope and scanning electron microscope furnished with an energy-dispersive spectral analyzer and the adhesion was detected by the scratch test method. The microstructures of the deposited coatings were also observed by a scanning electron microscope. The results show that when the coating is not oxidized and dense, the copper-coated graphite reinforced copper-based composite coating at 800 °C, 5.5 MPa, possesses the lowest surface roughness, the maximum thickness and the highest adhesion among the cold-sprayed coatings. In addition, the surface roughness, thickness and adhesion of the deposited coatings are all linear with particle velocity. 

/pdf/effect-of-cold-spray-parameters-on-surface-roughness-1nfx2ivp.pdf

Effect of Cold-Spray Parameters on Surface Roughness, Thickness and Adhesion of Copper-Based Composite Coating on Aluminum Alloy 6061 T6 Substrate

This study aims at improving the coating properties and cladding efficiency in composite material laser cladding. Using Taguchi orthogonal experimental design, the correlation between processing parameters and index of cladding quality had been investigated. By altering the input of laser power, scanning speed, gas flow, and tungsten carbide powder ratio in laser cladding setup, their influence on the micro-hardness and wear resistance of the clad as well as the cladding efficiency had been studied. This study achieved processing parameter optimization with grey relational analysis by combining multiple objectives. Results showed that the micro-hardness and wear resistance of the clad were significantly affected by the WC powder ratio in the composite. Also, the laser power denoted a significant impact on the cladding efficiency. To obtain the clad with maximum micro-hardness and minimum wear volume while also attaining the maximum cladding efficiency, grey relational analysis was utilized to combine these multiple objectives in optimization. The processing parameter set obtained from optimization met the targets and showed a small-scale error rate of 4.92% in the grey relational grade prediction. This study verified the applicability and provided the theoretical basis for multiple-objective optimization of the coating properties and cladding efficiency in composite laser cladding.

Multi-objective optimization of coating properties and cladding efficiency in 316L/WC composite laser cladding based on grey relational analysis

Laser cladding, a novel surface treatment technology, utilizes a high-energy laser beam to melt diverse alloy compositions and form a specialized alloy-cladding layer on the surface of the substrate to enhance its property. However, it can generate substantial residual stresses during the rapid cooling and heating stages, due to inadequate selection of cladding process parameters and disparities in thermophysical properties between the clad layer and substrate material, leading to the formation of various types of cracks. These cracks can significantly impact the quality and performance of the coating. This paper presents a comprehensive review of crack types and their causes in laser cladding coatings, and identifies that three primary sources of residual stresses, thermal stress, organizational stress, and restraint stress, are the fundamental causes of crack formation. The study proposes several strategies to control coating cracks, including optimizing the coating layer material, refining the coating process parameters, incorporating heat treatment, applying auxiliary fields, and utilizing numerical simulations to predict crack initiation and propagation. Additionally, the paper summarizes crack control methods for emerging structural materials and novel preparation processes. Lastly, the paper analyzes the prospects, technical approaches, and key research directions for effectively controlling cracks in laser cladding coatings.

/pdf/crack-formation-mechanisms-and-control-methods-of-laser-3acckfwb.pdf

Crack Formation Mechanisms and Control Methods of Laser Cladding Coatings: A Review

Enhanced corrosion resistance of high speed laser-cladded Ni/316L alloy coating by heat treatment

A solid-state cold-spray technique was employed for depositing the copper-coated graphite reinforced copper-based composite coatings on aluminum alloy 6061 T6 substrate under different process parameters. The optimum process parameters of the cold-sprayed coatings were predicted in terms of surface roughness, thickness and adhesion. The surface roughness was measured using a 3D profilometer, the thickness and element constitution were detected by an optical microscope and scanning electron microscope furnished with an energy-dispersive spectral analyzer and the adhesion was detected by the scratch test method. The microstructures of the deposited coatings were also observed by a scanning electron microscope. The results show that when the coating is not oxidized and dense, the copper-coated graphite reinforced copper-based composite coating at 800 °C, 5.5 MPa, possesses the lowest surface roughness, the maximum thickness and the highest adhesion among the cold-sprayed coatings. In addition, the surface roughness, thickness and adhesion of the deposited coatings are all linear with particle velocity.

Effect of Cold Spray Parameters on Surface Roughness, Thickness and Adhesion of Copper Based Composite Coating on Aluminium Alloy 6061 T6 Substrate

Microstructure evolution and high temperature corrosion behavior of FeCrBSi coatings prepared by laser cladding

Microstructure and properties of Ni60 alloy coating prepared by electromagnetic compound field assisted laser cladding

This paper presents a comprehensive comparison study on the dynamic performances of three planar 3-DOF parallel manipulators (PPMs): 3-RRR, 3-PRR, and 3-RPR. In this research work, the discrete time transfer matrix method (DT-TMM) is employed for developing dynamic models of the planar parallel manipulators. Numerical simulations using the virtual work principle and ADAMS 2016 software are performed to verify the DT-TMM dynamic model of PPMs. Numerous dynamic performance indices, including dynamic dexterity, the power requirement, energy transmission efficiency, and the joint force/torque margin, are proposed to compare the dynamic performance of three PPMs under the general circular and linear trajectories. The comprehensive analyses and comparisons show that: (1) the 3-RRR PPM has advantages in terms of a circular trajectory, offering the best dynamic dexterity performance, the smallest power requirement, and the second-highest energy transfer efficiency; (2) the 3-PRR PPM performs best in terms of a linear trajectory, offering the best dynamic dexterity, the smallest power requirement range, and the best drive performance; and (3) the 3-RPR PPM has the highest energy transfer efficiency and demonstrates better dynamic performance in a circular trajectory compared to a linear trajectory.

/pdf/comparison-of-the-dynamic-performance-of-planar-3-dof-j4nhwbwg.pdf

Comparison of the Dynamic Performance of Planar 3-DOF Parallel Manipulators

In order to investigate the corrosion mechanism in molten aluminum alloy, NiCrBSi coating was prepared on H13 tool steel by laser-cladding. The coating mainly contained γ-(Ni, Fe), Cr7C3, Ni3B, and CrB. Floret-shaped CrB and dendritic Cr7C3 were uniformly distributed in the Ni-based solid solution matrix, with Ni-Ni3B network eutectics separated around them. The corrosion test results in molten aluminum alloy at 1073 K revealed that NiCrBSi coating exhibited excellent corrosion resistance, which was attributed to its boride-containing phase composition and microstructure. Borides can help prevent the coating surface from being wetted by liquid aluminum at the early stage of corrosion. With the prolongation of the corrosion time, molten aluminum alloy began to wet the coating surface and react with it to form a transition layer. However, the dense network structure formed by CrB hard phases and boron-rich eutectics can effectively prevent liquid aluminum from intruding into the interior part of the coating. Meanwhile, the raised borides at the interface can also slow down the reaction between aluminum and the surrounding Ni-based matrix. Thus, the corrosion rate was relatively slow and a transition layer with the thickness of 140  μm was formed after 150 h of corrosion, while the inferior coating and H13 substrate still remained intact.

Corrosion behavior of laser-cladding NiCrBSi coating in molten aluminum alloy

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Papers

Microstructure evolution and high temperature corrosion behavior of FeCrBSi coatings prepared by laser cladding

Microstructure and properties of Ni60 alloy coating prepared by electromagnetic compound field assisted laser cladding

Comparison of the Dynamic Performance of Planar 3-DOF Parallel Manipulators

Corrosion behavior of laser-cladding NiCrBSi coating in molten aluminum alloy