Tunnel boring machine (TBM) cutter is the tooth of TBM, the service life of the cutter affects the construction progress and efficiency. In this study, the Ni-based tungsten carbide composite powder was deposited on the surface of the TBM cutter ring by laser cladding to improve the wear resistance. The microstructure of the coating was analyzed, the wear resistance was studied and compared with the substrate. A wear-resistant coating with low porosity was prepared on the surface of the 5Cr5MoSiV1 cutter ring, which has a good metallurgical bonding with the substrate. The main phases in the coating were γ-Ni, WC and W2C. Spherical WC and its decomposed WC and W2C small particles are widely distributed in the coating, effectively hindering the pressing and ploughing of hard rock particles, thereby improving the wear resistance of the coating. The calculated results of the volume loss before and after wear showed that the wear resistance of the cladding layer was about 7 times higher than that of the substrate. The results showed that laser cladding Ni-based WC is effective ways to improve the tribological properties of TBM cutter ring.

Microstructure and wear resistance of Ni-based tungsten carbide coating by laser cladding on tunnel boring machine cutter ring

A hybrid fuzzy multiple criteria decision-making approach for comprehensive performance evaluation of tunnel boring machine disc cutter

The Ni3Ta-TaC reinforced Ni-based coating is synthesized in-situ on the substrate of the shield tunneling machine cutter ring by laser cladding to improve its wear resistance. The microstructure and strengthening mechanism of Ni-Ta and Ni-Ta-C coatings were studied respectively. The wear resistance of the two coatings was studied and compared with the substrate. The Ni-Ta coating is mainly composed of γ-Ni, Ni3Ta and Ta phases, while the Ni-Ta-C coating is mainly composed of γ-Ni, Ni3Ta and TaC phases. The wear resistance of Ni-Ta coating and Ni-Ta-C coating is 2 times and 4 times higher than that of 5Cr5MoSiV1 steel, respectively. It is expected to improve the wear resistance of the shield cutter ring.

Microstructure and properties of in-situ synthesized Ni3Ta-TaC reinforced Ni-based coatings by laser cladding

TBM (Full face rock tunnel boring machine) is a large tunnel excavation lining complete equipment which has been widely used in many practical fields. The main components of TBM rock breaking are the disc cutters. Due to the harsh working environment of TBM, such as high temperature (400°C), wear, etc., the consumption of disc cutters is extremely high. Two welding methods used to repair cutters of TBM were analyzed in this paper: shielded metal arc welding (SMAW) and flux cored arc welding (FCAW). The microstructure at RT was investigated, the hardness, indentation modulus and wear resistance from RT to 400°C were also investigated. The results showed that the microstructure of FCAW hardfacing layers was finer. In the tests, the FCAW hardfacing layers showed better hardness and elastic modulus, both parameters reduced with increasing temperature. The FCAW hardfacing layers processed higher wear resistance from RT to 400°C. A thick oxide layer was observed, and it was partially removed when the temperature reached 400°C, and it has a certain protective effect on the worn surface. Therefore, the FCAW hardfacing layers are considered as a good choice due to the better mechanical performance from RT to 400°C.

/pdf/the-indentation-and-wear-performance-of-hardfacing-layers-on-oaenjnm2c9.pdf

The indentation and wear performance of hardfacing layers on H13 steel for use in high temperature application

In the rapidly evolving field of additive manufacturing (AM), the predictability of part properties is still challenging due to the inherent multiphysics complexity of the technology. This results in time-consuming and costly experimental guess-and-check approaches for manufacturing each individual design. Through synthesising advancements in the field, this review argues that numerical modelling is instrumental in mitigating these challenges by working in tandem with experimental studies. Unique hierarchical microstructures induced by extreme AM process conditions– including melt pool patterns, grains, cellular–dendritic substructures, and precipitates—affect the final part properties. Therefore, the development of microstructure-informed mechanical models becomes vital. Our review of numerical studies explores various modelling approaches that consider the microstructural features explicitly and offers insights into multiscale stress–strain analysis across diverse materials fabricated by powder bed fusion AM. The literature indicates a growing consensus on the key role of multiscale integrated process–structure–property–performance (PSPP) modelling in capturing the complexity of AM-produced materials. Current models, though increasingly sophisticated, still tend to relate only two elements of the PSPP chain while often focusing on a single scale. This emphasises the need for integrated PSPP approaches validated by a solid experimental base. The PSPP paradigm for AM, while promising as a concept, is still in its infantry, confronting multifaceted challenges that require in-depth, multidisciplinary expertise. These challenges range from accounting for multiphysics phenomena (e.g., advanced laser–material interaction) and their interplay (thermo-mechanical and microstructural evolution for simulating Type II residual stresses), accurately defined assumptions (e.g., flat molten surface during AM or purely epitaxial solidification), and correctly estimated boundary conditions for each element of the PSPP chain up to the need to balance the model’s complexity and detalisation in terms of both multiphysics and discretisation with efficient multitrack and multilayer simulations. Efforts in bridging these gaps would not only improve predictability but also expedite the development and certification of new AM materials.

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

The material of disc cutters is important to full-face tunnel boring machines (TBM). In recent years, disc cutters were optimized and tested by many scholars all around the world. H13(4Cr5MoSiV1) steel is widely used due to its excellent properties, especially in TBM disc cutters. In this paper, H13 steel with optimized composition was prepared and heat treatment. The high temperature compression of H13 steel was conducted at the temperatures ranging from 100 °C to 700 °C, with strain rate at 0.01 s−1. The stress-strain curves, Rockwell hardness and microstructure of H13 steel after compression were obtained and analyzed. The results showed that the compression strength and hardness decreased as the temperature increased; and the compression strength, hardness and ductility decreased rapidly between 600 °C and 700 °C, HR700 (the hardness of H13 steel at 700 °C) only reached 33.23 HRC. It is not recommended for TBM disc cutters to work in an environment over 600 °C.

https://www.mdpi.com/2076-3417/8/10/1877/pdf

The Preparation of H13 Steel for TBM Cutter and the Performance Test Close to Working Condition

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The Preparation of H13 Steel for TBM Cutter and the Performance Test Close to Working Condition