A 3D finite element analysis of thermally induced residual stress distribution in stainless steel coatings on a mild steel by laser hot wire cladding

Laser hot wire cladding is an efficient and energy-saving additive manufacturing process, which is used in coating, repair, and 3D printing. In this study, 308L stainless steel wire was deposited on the low carbon steel substrate using Laser hot wire cladding technology. The microstructure evolution and microhardness changes in the heat-affected zone of the substrate and the cladding layer near the laser cladding interface were studied in detail by using optical microscopy, electron backscatter diffraction and microhardness tests. The phase transformations and the relationship between microstructure and mechanical properties of the cladding layer were discussed. Owing to the dual effect of temperature gradient and cooling rate, the grain morphology in the central region of the cladding layer is equiaxed, while the edge region is mostly columnar dendritic morphology along the structural direction. There is a dilution zone composed of single austenite near the interface of the cladding layer. In the cladding layer, the ferrite-austenite solidification mode is dominant, and the austenite-ferrite solidification mode is also found in local areas. The carbon migration process from the substrate to the cladding layer promotes the austenite-ferrite mode. The heat-affected zone microstructure consists mainly of ferrite and tempered bainite, and slatted martensite can be observed near the interface. The electron backscatter diffraction results demonstrate the existence of martensite in the heat-affected zone. The texture is more apparent in the cladding layer, while the heat-affected zone contains more residual strain and higher dislocation density. The average grain size in the heat-affected zone region is about 4 μm, while the average grain size in the cladding layer is above 14 μm. The hardness of the heat-affected zone near the interface is the highest due to numerous factors, such as grain size, microstructure transformation and dislocation density. The yield strength increases with the decrease of grain size and texture strength, demonstrating the correlation between microstructure and mechanical properties.

Research on interface characteristics of 308L stainless steel coatings manufactured by laser hot wire cladding

Hot-wire laser welding is additive manufacturing (AM) technique that allows for the direct creation of complicated objects by melting layers of wire. This process is characterized by the use of hot-wire process, unification with the laser welding (LW) process in AM process. The empirical investigation of AM employing a hot-wire laser welding on a titanium alloy (grade 2) workpiece is presented in this research. There are three parameters in the hot-wire laser process namely wire current, welding speed, and wire feeding speed; this research examined porosities, microhardness, tensile stress, and residual stress. The filler metal used titanium AMS (American welding society) 4951F welding wire of grade 2 and measures 1.6 mm in diameter. Finally, the suitable hot wire laser welding parameters should be 0.183 cm s−1 for the welding speed, the wire current of 40 A, and the wire feeding speed of 1.00 m min−1 are 0.183 cm s−1 for welding speed, 40 A for wire current, and 1.00 m min−1 for wire feeding speed, which will give the average Vicker microhardness of 321.00–345.80 HV, the average tensile strength of 432.02 MPa (substrate); 670.30 MPa (horizontal direction), 497.39 MPa (vertical direction).

Experimental investigation of hot-wire laser deposition for the additive manufacturing of titanium parts

The aim of this research was to develop a high-efficiency and high-material-utilization additive manufacturing technology using the hot-wire laser method. In this study, the optimization of process conditions using a combination of a high-power diode laser with a relatively large laser spot hot-wire system was investigated. The effects of welding parameters such as the laser power, process speed, and wire feeding rate (wire feeding speed/process speed) on the bead appearance evaluation and the cross-sectional characteristics ( e.g. effective width, effective height, maximum height, and near net shape rate) were studied in detail. The process phenomena of the three-layer and multi-layer deposition were investigated by in-situ observation via a high-speed camera. Energy density input and wire feeding rate were found to be dominant parameters influencing both the stability of phenomena and bead appearance. With the increase of process speed, the effective width decreases, the effective height, maximum height, and the near net shape rate increases. Additionally, all measured values of the wire feeding rate of 30 improve compared with the values of the wire feeding rate of 20. The near net shape rate increased and the effective width over 10mm of three-layer deposition for the laser spot width of 11 mm was obtained with suitable process parameters. The defect-free 15-layer wall modeling of more than 50 mm in height, 8 mm in width, and 250 mm in length was obtained with high efficiency using the optimum conditions by the hot-wire laser method.

Derivation of appropriate conditions for Additive Manufacturing technology using hot-wire laser method

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Derivation of appropriate conditions for Additive Manufacturing technology using hot-wire laser method