Heat-treated microstructure and mechanical properties of laser solid forming Ti-6Al-4V alloy

The effects of heat treatment on the microstructure and mechanical properties of laser solid forming （LSF） Ti-6Al-4V alloy were investigated The influences of the temperature and time of solution treatment and aging treatment were analyzed. The results show that the microstructure of LSFed samples consists of Widmanstatten α laths and a little acicular in columnar prior β grains with an average grain width of 300 μm, which grow epitaxiaUy from the substrate along the deposition direction （27）. Solution treatment had an important effect on the width, aspect ratio, and volmne fraction of primary and secondary a laths, and aging treatment mainly affects the aspect ratio and volume fraction of primary α laths and the width and volume fraction of secondary a laths. Globular a phase was first observed in LSFed samples when the samples were heat treated with solution treatment （950℃, 8 h/air cooling （AC）） or with solution treatment （950℃, 1 h/AC） and aging treatment （550℃, above 8 h/AC）, respectively. The coarsening and globularization mechanisms of a phase in LSFed Ti-6Al-4V alloy during heat treatment were presented. To obtain good integrated mechanical properties for LSFed Ti-6Al-4V alloys, an optimized heat treatment regimen was suggested.

Effects of laser energy density on forming accuracy and tensile strength of selective laser sintering resin coated sands

Baozhu sand particles with size between 75 μm and 150 μm were coated by resin with the ratio of 1.5 wt.% of sands. Laser sintering experiments were carried out to investigate the effects of laser energy density(E = P/v), with different laser power(P) and scanning velocity(v), on the dimensional accuracy and tensile strength of sintered parts. The experimental results indicate that with the constant scanning velocity, the tensile strength of sintered samples increases with an increase in laser energy density; while the dimensional accuracy apparently decreases when the laser energy density is larger than 0.032 J·mm-2. When the laser energy density is 0.024 J·mm-2, the tensile strength shows no obvious change; but when the laser energy density is larger than 0.024 J·mm-2, the sample strength is featured by the initial increase and subsequent decrease with simultaneous increase of both laser power and scanning velocity. In this study, the optimal energy density range for laser sintering is 0.024-0.032 J·mm-2. Moreover, samples with the best tensile strength and dimensional accuracy can be obtained when P = 30-40 W and v = 1.5-2.0 m·s-1. Using the optimized laser energy density, laser power and scanning speed, a complex coated sand mould with clear contour and excellent forming accuracy has been successfully fabricated.

EXPERIMENTAL RESEARCH AND NUMERICAL SIMULATION OF LASER SHOCK FORMING OF TA2 TITANIUM SHEET

Laser shock forming （ISF） was a new technique realized by applying an impulsive pressure generated by laser-induced shock wave on the surface of metal sheet. LSF of metal sheet was investigated with experiments and numerical simulation. The basic theories were introduced; the surface quality and deformation of the processed titanium sample （TA2） were examined; ABAQUS was used to simulate ISF and the central displacement of the shocked region was measured and compared with the simulation. Overlapped ISF treatment was experimentally carried out to produce groove and simulation. The results showed that the surface quality and the microstructure with single laser pulse had no remarkable change, and ablation was observed on the surface of the sample with overlapped pulses. The deformation observed in the numerical simulation agreeed with that observed in the experimental measurement quite well.

A Study on Super Speed Forming of Metal Sheet by Laser Shock Waves

Metal sheet plastic deformation or forming is gener at ed through a mechanical pressure or a thermal variation. These pressure variatio ns or thermal variations can be created by a variety of means such as press form ing, hydroforming, imploding detonation and so on. According to the magnitude of the strain rates all these forming methods can be divided into quasi-static fo rming and dynamical forming. Up to now there are no reports of forming methods w ith the strain rates above 10 5sec -1, even though the exploding forming. In this article, we work on a dynamic super-speed forming method driven by lase r shock waves and advanced a novel concept of laser shock forming. The initial o bservation of the laser shock forming is done through a bugle testing with speci mens of SUS430 sheet metal, using a neodymium-glass laser of pulse energy 10J～ 3 0J and duration of 20 ns (FWHM). The investigation revealed that the plastic de formation during the laser shock forming is characterized as ultrahigh strain ra te up to 10 7sec -1. We indicate that plastic deformation increases nonlin early when the energy density of the laser varies. By investigating the hardness and residual stress of the surfaces, we conclude that laser shock forming is a combination technique of laser shock strengthening and metal forming for introdu cing a strain harden and a compressive residual stress on the surface of the wor k-piece, and the treated surface by laser shock forming has good properties in fatigue and corrosion resistance. This technique can achieve forming wit h or without mould.

Fabrication of directional solidification components of nickel-base superalloys by laser metal forming

Straight plates, hollow columns, ear-like blade tips, twist plates withdirectional solidification microstructure made of Rene 95 superalloys were successfully fabricatedon Nickel-base superalloy and DD3 substrates, respectively. The processing conditions for productionof the parts with corresponding shapes were obtained. The fabrication precision was high and thecomponents were compact. The solidification microstructure of the parts was analyzed by opticalmicroscopy. The results show that the solidification microstructure is composed of columnardendrites, by epitaxial growth onto the directional solidification substrates. The crystallographyorientation of the parts was parallel to that of the substrates. The primary arm spacing was about10 mum, which is in the range of superfine dendrites, and the secondary arm was small or evendegenerated. It is concluded that the laser metal forming technique provides a method to manufacturedirectional solidification components.

Edge effects of metal plate in laser forming

To search for the new scanning plan that can reduce the bending angle variation and the bending curvatures of the bending edge, an explanation for the causes of the edge effects was given. Six new scanning strategies were proposed through the change of the scanning length of middle and two ends based on the above analyses. Numerical simulations were carried out to study the edge effects using the six new scanning strategies. The simulation results show that the new scanning strategies can improve effectively the quality of the forming parts.

NUMERICAL INVESTIGATION OF STRAIGHT-LINE LASER FORMING UNDER THE TEMPERATURE GRADIENT MECHANISM

Laser forraing is a new flexible and dieless forming technique. To achieve the high accuracy forming, the temperature gradient mechanism （TGM） is studied. In the analysis of TGM, the plate bends about x-axis and about y-axis as well. To understand the deformation trend, the numerical simulation of deformation of plate is conducted by choosing different laser powers, laser spot diameters, scanning speeds, lengths, widths and thicknesses. From the results of simulation, it can be seen that the laser spot diameter, the scanning speed, laser power and thickness of plate play dominant roles in the laser forming process. However, the bending angles αx and αy show different trends with the variation of parameters. In addition, in comparison with above four parameters, the effect of length and width of plate on the beading angle may be neglected, but their effects are significant for the bending radius R.

Influence of processing parameters on deposition characteristics of Inconel 625 superalloy fabricated by laser solid forming

A series of single track clads of Inconel 625 alloy were fabricated by laser solid forming.To achieve the high dimensional accuracy and excellent mechanical properties,the effect of processing parameters on the geometry,the formation of Laves phase and the residual stress was investigated.The results show that laser power and scanning speed had a dramatical influence on the width and height of single-track clads.According to the columnar to equiaxed transition curve of Inconel 625,the grain morphology can be predicted during the LSF process.With the increasing laser power and the decreasing scanning speed,the segregation degree of Si,Nb,Mo,the volume fraction and size of Laves phase increased.Vickers indentation was used to demonstrate that optimizing processing parameter can achieve the minimum residual tensile stress.

Numerical Simulation Research on Laser Shock Forming of Thin Metal Sheet

Laser shock forming (LSF) of sheet metal is a new technique realized by applying an impulsive pressure generated by laser-induced shock wave on the surface of metal sheet. LSF of brass sheet metal was investigated using a Q-switched Nd:YAG laser with an energy per pulse of 15～50 joules. ABAQUS software was used to simulate laser shock forming process. The central displacement of the shocked region is measured and compared with the simulation. The higher pulse energy, the higher central displacement of the shocked region were obtained. The deformation of the simulation matches the experiment quite well.

FEM SIMULATION FOR LASER FORMING PROCESSING

Laser forming involves heating sheet metal workpiece along a certain path with adefocused laser beam directed irradiate to the surface. During laser forming, a tran-sient temperature fields is caused by the irradiation and travelling of a laser beam.Consequently, thermal expansion and contraction take place, and allows the thermal-mechanical forming of complex shapes. This is a new manufacturing technique thatforming metal sheet only by thermal stress. Therefore, the analysis of temperaturefields and stress fields are very useful for studying the forming mechanism and con-trolling the accuracy of laser forming. The non--liner finite element solver, MARC, isemployed to solve the thermal--mechanical analysis. Using this model, the stress andstrain distribution of pure aluminum plate with different thickness are analyzed. Theinfluence of scanning speed on temperature fields and plastic strain of metal sheet un-der the condition of constant line energy are also presented. Numerical results agreewell with the experimental results.

Solidification Microstructure of Rene95 Superalloy by Laser Metal Forming

Rene95 powder and different substrates were selected to be conducted by the laser metal forming technique. It is found that the cladding layers with either columnar or equiaxed grains can be obtained under different solidification conditions. As the crystallography orientation of the substrate influences that of the cladding layers strongly. Multi-grain cladding layers can be obtained on the multi-grain substrate, while directional solidification columnar or even single crystal cladding layer can be achieved on the directional solidification or single crystal substrate.The mechanism of microstructure formation in the cladding layer was furtherly investigated according to the columnar/equiaxed transition profile. In addition,an ear-like single crystal component was manufactured using the DD3 single crystal as substrate. The yield strength at room temperature was examined on the heat-treated slice sample. The results indicate that the yield strength is about 97.9% of that of the powder metallurgical tensile sample while the plasticity overpasses 80% of the powder metallurgical tensile sample.

Improving a Laser Machine for Laser Forming of Metals

Laser forming is a flexible metal forming process without a die. At present, for this innovative process no exclusive equipment is commercially available. In this paper, some improving measures including temperature monitoring system, shape monitoring system, cooling system and rotary segment have been proposed on the basis of the general NC laser machine in order to meet the special requirements for laser forming of metals. The improved laser machine may be conveniently used to control dynamically and record the whole laser forming process of metals.

Laser rapid forming of low cost hydride-dehydride titanium alloy powder

Low cost hydride-dehydride (HDH) Ti-6Al-4V (Ti-64) alloy powder was employed to investigate the metallurgical quality and mechanical properties of laser formed samples. With appropriate control of the laser forming processing parameters and the loose density of HDH powder, two kinds of defect, i.e. porosity and ill-bonding, can be avoided. Rare earth Nd powder was added to HDH Ti-64 powder to purify laser formed alloy. The results show that with a few additive of Nd, the microstructure of laser formed alloy changes from Widmanstatten morphology to a basket weave microstructure. Accordingly an appropriate addition of Nd is effective to improve both the strength and ductility of laser formed HDH Ti-64 alloy. The values of tensile test meet the wrought specification with the content of Nd ranging from 0.1%-0.2%(mass fraction).

Integration system research and development for three-dimensional laser scanning information visualization in goaf

An integration processing system of three-dimensional laser scanning information visualization in goaf was developed. It is provided with multiple functions, such as laser scanning information management for goaf, cloud data de-noising optimization, construction, display and operation of three-dimensional model, model editing, profile generation, calculation of goaf volume and roof area, Boolean calculation among models and interaction with the third party soft ware. Concerning this system with a concise interface, plentiful data input/output interfaces, it is featured with high integration, simple and convenient operations of applications. According to practice, in addition to being well-adapted, this system is favorably reliable and stable.

Effect of Intermediate Heat Treatment Temperature on Microstructure and Notch Sensitivity of Laser Solid Formed Inconel 718 Superalloy

Inconel 718 superalloys deposited by laser solid forming （LSF） were heat treated with solution treatment,intermediate heat treatment （IHT） and two-stage aging treatment in sequence （SITA heat treatment）.The effect of IHT temperature on microstructure,tensile property and notch sensitivity of LSFed Inconel 718 superalloy at 500 ℃ were investigated.As-deposited columnar grains have transformed to equiaxed grains and the grains were refined due to the recrystallization during the SITA heat treatment.It is found that the size and amount of δ phase dispersed at grain boundaries decreased with the increasing of IHT temperature,and δ phase disappeared when the IHT temperature reached 1 020 ℃.The ultimate tensile strength （UTS） and yield strength （YS） of smooth samples increased to a maximum when the IHT temperature reached 980 ℃ and then decreased slightly to a minimum when the IHT temperature was 1 000 ℃,and followed by slight increasing again till the IHT temperature reached 1 020 ℃,resulted from the competition of precipitation strengthening effect of γ″ and γ＇ phase and the grain boundary weakening effect caused by the gradual disappearance of δ phase with increasing the IHT temperature.The notch sensitivity factor （qe） decreased but still greater than 1 as the IHT temperature increased,which is attributed to the decrease of the size and amount of δ precipitation.

Superplastic formability of Ti-6Al-4V butt-welded plate by laser beam welding

The superplasticity of Ti-6Al-4V butt-welded plates by laser beam welding(LBW)was studied in virtue of hot tensile tests and superplastic bulging tests.Furthermore,microstructural evolution of weld metal upon superplastic forming was systematically analyzed via metallographical tests and scanning electron microscope(SEM).The relation between the microstructure of weld metal and its superplastic ability was discussed.The experimental results show that Ti-6Al-4V butt-welded plates by LBW possess superplasticity.The maximum elongation is up to 154%and the maximum bulge height can be up to 1.81 times the internal radius of the female die.There is an optimum value of the bulge height for bulging gas pressure.

Ore-forming Fluid Characteristics of the Saishitang Cu-polymetallic Deposit in Qinghai Province,China

Saishitang Cu-polymetallic deposit is located in the southeast section of Late Paleozoic arcfoid in the southeastern margin of Qaidam platform. Accoring to the geological process of the deposit, four mineralization episodes were identified： melt/fluid coexisting period （O）, skarn period （A）, first sulfide period （B） and second sulfide period （C）, and 10 stages were finally subdivided. Three types of inclusions were classified in seven stages, namely crystal bearing inclusions （type I）, aqueous inclusions （type Ⅱ） and pure liquid inclusions （type Ⅲ）. Type I and Ⅱ inclusions were observed in stage O1, having homogenization temperature from 252 to 431℃, and salinities ranging from 24.3% to 48.0%. Type I inclusion was present in stage A1, having homogenization temperature from 506 to 548℃, and salinities ranging from 39.4% to 44.6%. In stage B1, type Ⅱ and Ⅲ inclusions were observed, with homogenization temperature concentrating between 300-400℃, and salinities from 0.4% to 4.3%. Type II inclusions were present in stage B2, with homogenization temperature varying from 403 to 550℃. In stage C1, type I and II inclusion commonly coexisted, and constituted a boiling inclusion group, having homogenization temperatures at 187-463℃, and salinities in a range of 29.4%-46.8% and 2.2%-11.0%. Type II and III inclusions were developed in stage C2, having homogenization temperature at 124-350℃, and salinities ranging between 1.6% and 15.4%. In stage C3, type Ⅱ and Ⅲ inclusions were presented, with a homogenization temperature range of 164-360℃, and salinities varying from 4.0% to 11.0%. The results of micro-thermal analysis show that fluids are characterized by high temperature and high salinity in stage O1 and A1, and experienced slight decrease in temperature and dramatic decrease in salinity in stage B1 and B2. In stage C1, the salinity of fluid increased greatly and a further decrease of temperature and salinity occurred in stage C2 and C3. Fluids boiled in stage C1. With calculated pressure of 22 MPa from the trapping temperature of 284- 289℃, a mineralization depth of 2.2 km was inferred. Results of Laser Raman Spectroscopy show high density of H2_O, CH_4 and CO_2 were found as gas composition. H-O isotope study indicates the ore- forming fluids were the mixture of magmatic water and meteoric water. Physicochemical parameters of fluids show oxygen and sulfur fugacity experienced a decrease, and redox state is weakly reducing. Along with fluid evolution, oxidation has increased slightly. Comprehensive analysis shows that melt exsolution occurred during the formation of quartz diorite and that metal elements existed and migrated in the form of chlorine complex. Immiscible fluid separation and boiling widely occurred after addition of new fluids, bringing about dissociation of chlorine-complex, resulting in a great deal of copper precipitation. In conclusion, Saishitang deposit, controlled by regional tectonics, is formed by metasomatism between highly fractionated mineralization rock body and wall rock, and belongs to banded skarn Cu-polymetallic deposit.Abstract： Saishitang Cu-polymetallic deposit is located in the southeast section of Late Paleozoic arcfoid in the southeastern margin of Qaidam platform. Accoring to the geological process of the deposit, four mineralization episodes were identified： melt/fluid coexisting period （O）, skarn period （A）, first sulfide period （B） and second sulfide period （C）, and 10 stages were finally subdivided. Three types of inclusions were classified in seven stages, namely crystal bearing inclusions （type I）, aqueous inclusions （type Ⅱ） and pure liquid inclusions （type Ⅲ）. Type I and II inclusions were observed in stage O1, having homogenization temperature from 252 to 431℃, and salinities ranging from 24.3% to 48.0%. Type I inclusion was present in stage A1, having homogenization temperature from 506 to 548℃, and salinities ranging from 39.4% to 44.6%. In stage B1, type II and III inclusions were observed, with homogenization temperature concentrating between 300-400℃, and salinities from 0.4% to 4.3%. Type II inclusions were present in stage B2, with homogenization temperature varying from 403 to 550℃. In stage C1, type I and II inclusion commonly coexisted, and constituted a boiling inclusion group, having homogenization temperatures at 187-463℃, and salinities in a range of 29.4%-46.8% and 2.2%-11.0%. Type II and III inclusions were developed in stage C2, having homogenization temperature at 124-350℃, and salinities ranging between 1.6% and 15.4%. In stage C3, type II and Ⅲ inclusions were presented, with a homogenization temperature range of 164-360℃, and salinities varying from 4.0% to 11.0%. The results of micro-thermal analysis show that fluids are characterized by high temperature and high salinity in stage O1 and A1, and experienced slight decrease in temperature and dramatic decrease in salinity in stage B1 and B2. In stage C1, the salinity of fluid increased greatly and a further decrease of temperature and salinity occurred in stage C2 and C3. Fluids boiled in stage C1. With calculated pressure of 22 MPa from the trapping temperature of 284- 289℃, a mineralization depth of 2.2 km was inferred. Results of Laser Raman Spectroscopy show high density of H_2O, CH_4 and CO_2 were found as gas composition. H-O isotope study indicates the ore- forming fluids were the mixture of magmatic water and meteoric water. Physicochemical parameters of fluids show oxygen and sulfur fugacity experienced a decrease, and redox state is weakly reducing. Along with fluid evolution, oxidation has increased slightly. Comprehensive analysis shows that melt exsolution occurred during the formation of quartz diorite and that metal elements existed and migrated in the form of chlorine complex. Immiscible fluid separation and boiling widely occurred after addition of new fluids, bringing about dissociation of chlorine-complex, resulting in a great deal of copper precipitation. In conclusion, Saishitang deposit, controlled by regional tectonics, is formed by metasomatism between highly fractionated mineralization rock body and wall rock, and belongs to banded skarn Cu-polymetallic deposit.

Microstructure and high temperature mechanical properties of laser rapidly formed Ti-6A1-4V alloy

Several tensile samples were prepared using laser rapid forming (LRF) with Ti-6Al-4V alloy as powder material, and the samples were annealed. The microstructure and high temperature mechanical properties of laser formed Ti-6Al-4V alloy through annealing treatment were investigated. The short-term and long-term tensile tests at 350℃were performed. The results show that the microstructure of LRF samples consists of the large columnar priorβgrains which grow epitaxially from the substrate along the deposition direction. There are Widmanstatten a laths in priorβgrains, but a laths in annealed microstructure are coarser, and their aspect ratio is lower than that in as-deposited microstructure. In addition, the priorβgrain boundary is also coarsened and broken off through the annealing treatment. The high temperature mechanical properties of the annealed LRF samples exceed those of casting alloy significantly, especially the stress-rupture lifetime reaches 661.7 h even while the test stress increases from initial value of 490 MPa to the final stress of 800 MPa gradually.

STUDY OF NON-CONTACT MEASUREMENT OF FREE-FORM SURFACES

A non contact three dimensional measurement method is presented in this paper.This system consists of a laser triangulation probe,a probe head and a coordinate measuring machine (CMM).The measurement principle of the system is discussed,and a system calibration method employing a reference ball is proposed.The geometric model involving four frames is established to calculate the data points based on the reading of the laser probe and position information from the CMM.A measuring experiment for gesso free form surface using this system is carried out.

EXPERIMENTAL STUDY ON MACRO AND MICRO-STRUCTURE OF METALLIC PARTS BUILT BY LOW-POWER LASER CLADDING

A low-power CO_2 laser is used to deposit Fe powder and mixture of Fe andcarbon powder on substrates respectively, and the macro and micro-structure of the formed samplesare investigated. It is demonstrated that most grains of these samples are equi-axed. This isderived from the high nucleation velocity in the shallow melt pool besides rapid solidification ofthe liquid-state alloy or metal. Bainitic structure, combination of pearlite and ferrite structureand ferrite structure are seen respectively in the samples involving various amounts of carbon owingto no martensitic transformation in these small samples.