Coarse WC Particles Ceramic-Metal Composite Coating by Laser Cladding

The coarse WC particles ceramic-metal com- posite coatings with WC density of 67 wt-% and thickness of 1.0-1.2 mm have been cladded on 20Ni4Mo steel surface by a 2 kW CO_2 laser.The sintered WC particles with the size of 600-1000 μm are chosen as the main strengthening phase, Ni-base self-flux alloy as the binder in the compo- site coatings.The microstructure and microhardness of both WC particles and binder are analysed.The rigid ball indention with acoustic emission technique is used to evaluate the brittleness of the coating.Finally,the abrasive wear resistance of the coating is tested.Besides,the coatings with the same ratio and size of WC parti- cles in low carbon steel tube rod were cladded on 20Ni4Mo steel by atomic hydrogen welding tech- nique and analysed by the same way,their results are compared.

Ceramic-Metal Composite Coating by Laser Cladding

Four kinds of ceramics (silicon carbide, boron carbide, aluminum oxide and tungsten carbide) were added into Ni base self-fluxing alloy as reinforcing materials in order to obtain metalceramic composite coating by means of laser cladding. A lot of experiments have been carried out to test the processability of the four kinds of ceramics with different sizes and contents. The microstructures of sintered tungsten carbide (S-WC) and cast tungsten carbide (C-WC) reinforced Ni base alloy coatings were analysed, the distortion regulation of laser clad specimens was revealed. The wear resistance of the composite coating has been tested.

Microstructure and mechanical properties of Ni-based composite coatings reinforced by in situ synthesized TiB_2 + TiC by laser cladding

A Ni-based composite coating reinforced by in situ synthesized TiB2 and TiC particles was fabricated on Ti6A14V by laser cladding. An attempt was made to correlate the thermodynamic predictions and experimental observation. The micro- structure and the microhardness profile across the coating were investigated by means of X-ray diffraction （XRD）, scanning electron microscopy （SEM）, energy dispersive spectroscopy （EDS）, and a hardness tester. It is found that the coating mainly consists of a large number of reinforcements （black blocky TiB2, flower-like or equiaxial TiC, and fine acicular CrB） and the 7 matrix. The hardness of TiB2, TiC, and CrB reinforcements is much higher than that of the 7 matrix. The dispersive distribu- tion of such high hardness reinforcements causes the increase in hardness of the whole coating. The average value of the hard- ness is approximately Hv0.2 700 in the coating. The hardness of the coating is obviously higher than that of the substrate due to the dispersion strengthening of reinforcements.

Microstructural characterization of titanium matrix composite coatings reinforced by in situ synthesized TiB + TiC fabricated on Ti6Al4V by laser cladding

Titanium-based composite coatings reinforced by in situ synthesized TiB and TiC particles between titanium and B4C were successfully fabricated on Ti6Al4V by laser cladding. Phase constituents of the coatings were predicted by thermodynamic calculations in the Ti-BnC-Al and Ti-B-C-Al systems, respectively, and were validated well by X-ray diffraction （XRD） analysis results. Microstructural and metallographic analyses were made by scanning electron microscopy （SEM） and electron probe micro-analysis （EPMA）. The results show that the coatings are mainly composed of α-Ti cellular dendrites and the eutecticum in which a large number of needle-shaped TiB and a few equiaxial TiC particles are embedded. C is enriched in α-Ti cellular dendrites and far exceeds the theoretical maximum dissolubility, owing to the extension of saturation during laser cladding. The coatings have a good metallurgical bond with the substrate due to the existence of the dilution zone, in which a great amount of lamella β-Ti grains consisting of a thin needle-shaped martensitic microstructure are present and grow parallel to the heat flux direction; a few TiB and TiC reinforcements are observed at the boundaries of initial β-Ti grains.

Microstructure and formation mechanism of titanium matrix composites coating on Ti-6Al-4V by laser cladding

Laser cladding experiments were done on a 5-kW continuous wave CO2 laser to synthesize TiC and TiB rein- fowed titanium matrix composite coatings on Ti-6AI-4V alloy with a mixture of Ti and B4C precursor powder. The ther- modynamics of the reactions were calculated and analyzed. The microstructure and phase evolution of TiB and TiC com- posites were investigated. The results showed that the chemical reaction between Ti and B4C would release much heat, and these compounds, TiC, TiB, and small amount of TiB2, can be formed on the surface of Ti-6AI-4V alloy if the supplied en- ergy is sufficient to excite the reaction among the initial products. A good metallurgical bond between the coating and the substrate can be achieved. The microhardness of coating was irregular and the maximum value was approximately HV600.

Microstructure of Cu-based Amorphous Composite Coatings on AZ91D Magnesium Alloy by Laser Cladding

To improve the sliding wear resistance of AZ91D magnesium alloy, Cu-based amorphous composite coatings made of CuaTTi34Zr11Nis and Cu47Ti34Zr11Ni8＋20 wt pct SiC powders were fabricated on AZ91D magnesium alloy by laser cladding, respectively. SEM （scanning electron microscopy）, EDS （energy dispersive X-ray spectroscopy）, XRD （X-ray diffraction） and TEM （transmission electron microscopy） techniques were employed to study the phases of the coatings. The results show that the coatings mainly consist of amorphous phase and different intermetallic compounds. The reason of formation of amorphous phase and the function of SiC particles were explained in details.

Microstructure and properties of WC-12Co composite coatings prepared by laser cladding

A comprehensive study of the phase composition, microstructure evolution, microhardness and wear performance of WC-12 Co composite coatings fabricated by laser cladding using coaxial powder-feed mode was presented. It was shown that a combination of high scan speed and high laser energy density made WC on the edge of WC-12 Co composite powders partially melt in liquid Co and 304 stainless steel matrix, and then new carbides consisting of lamellar WC and herringbone M3 W3 C(M=Fe,Co) were formed. Meanwhile, WC-12 Co composite coatings with no porosity, cracks and drawbacks like decarburization were obtained, showing high densification and good metallurgical bonding with the substrate. Furthermore, a considerably high microhardness of HV0.3 1500-1600, low coefficient of friction of 0.55 and wear rate of(2.15±0.31)×10-7 mm3/(N·m) were achieved owing to the synergistic effect of excellent metallurgical bonding and fine microstructures of composite coating under laser power of 1500 W.

Fabrication and microstructure of Fe-based amorphous composite coatings by laser cladding

Fe-based amorphous composite coatings were fabricated on AISI 1045 steel by laser cladding. The results of the X- ray diffraction and transmission electron microscopy analyses .show the coating is composed of an amorphous phase in majority and a nanocrystaUine phuse in m,inority. Phase composition of the coating changes along the depth of the coating. The reasonable scanning speed for fabricating an amorphous composite coating is 3 500 mm/min when the laser power is 4 800 W and the laser beam diameter is 2 mm. If the scanning speed is lower than 3 500 mm/min, the intensity of the two main diffraction peaks in X-ray diffraction patterns of the coatings decreases with the scanning speeds increasing. At the same time, a broad halo peak emerges and enlarges. High laser power and fast scanning speed are the essential conditions of amorphization. The coating exhibits high microhardness.

Laser Cladding Al-Si/Al_2O_3-TiO_2 Composite Coatings on AZ31B Magnesium Alloy

To improve the wear resistance and corrosion resistance of magnesium alloys, a 5 kW continuous wave CO2 laser was used to investigate the laser surface cladding on AZ31 B magnesium alloys with Al-Si/Al2O3-TiO2 composite powders. A detailed microstructure, chemical composition, and phase analysis of the composite coatings were studied by scanning electron microscopy （SEM）, energy dispersive spectroscopy （EDS）, and X-ray diffraction （XRD）. The laser cladding shows good metallurgical bonding with the substrate. The composite coatings are composed of Mgl7Al12, Al3Mg2, Mg2Si, Al2O3, and TiO2 phases. Compared to the average microhardness （50HV0.05） of the AZ3 1 B substrate, that of the composite coatings （230HV0.05） is improved significantly. The wear resistances of the surface layers were evaluated in detail. The results demonstrate that the wear resistances of the laser surface-modified samples are considerably improved compared to the substrate. It also show that the composite coatings exhibit better corrosion resistance than that of the substrate in 3.5wt% NaCI solution.

Dynamics of Gradient Bioceramic Composite Coating on Surface of Titanium Alloy by Wide-Band Laser Cladding

The gradient bioceramic coating was prepared on the surface of titanium alloy using wide-band laser cladding.The dynamics of gradient bioceramic composite coating containing hydroxyapatite(HA)prepared with mixture of CaHPO4·2H2O and CaCO3 under the condition of wide-band laser was studied theoretically.The corresponding mathematical model and its numerical solution were presented.The examination experiment showed that HA bioceramic composite coatings can be obtained by appropriately choosing wide-band laser cladding parameters.The microstructure and surface morphology of HA bioceramic coating were observed by SEM and X-ray diffraction.The experimental results showed that the bioceramic coating is composed of HA,β-TCP,CaO,CaTiO3 and TiO2.The surface of bioceramic coating takes coral-shaped structure or short-rod piled structure,which helps osteoblast grow into bioceramic and improves the biocompatibility.

Residual Thermal Stresses of Laser Cladding of Intermetallic-Ceramic Composite Coatings

The stresses in laser cladding of Ni3Al-WC composite coating co and in heat affect zone (HAZ) σh have been induced based on considering the influences of laser processing parameters power P and beam traverse speed v.According to the calculated results, certain limits of P and v are necessary in order to obtain crack free coatings. It agrees well with the experimental results.

Microstructure and Tribological Properties of In-situ Synthesized TiB_2- TiC /Ni Based Composite Coating by Laser Cladding

A TiB2 and TiC particles reinforced Ni based composites coating was prepared on TC4 alloy surface by chemical reaction among Ti, B and C elements using laser cladding technique. Microstructural analysis showed that the sizes of in-situ synthesized TiB2 and TiC particles ranged within 5~10um and l^2um, respectively, while both the two kinds of particles were uniformly distributed in the clad layer. The measurement of microhardness and wear and friction properties indicated that the microhardness of laser clad layer was HV900-1100, being three times of that of the TC4 alloy; the friction coefficient of the laser clad layer in air and in vacuum (10~5 Pa) ranged within 0.2-0.3 and 0.3-0.5, respectively; the wear rate in terms of mass loss was considerably lower than that of the TC4 alloy both in air and in vacuum environment.

Characterization of gradient Ni-Fe/SiC composite coating on mild steel by thermal spraying in combination with laser cladding

Metal matrix composite coating Ni-Fe/SiC was prepared on an iron-based substrate bythermal spraying combined with laser cladding,using SiC particulates as the reinforcing agent.The micro-structures of the coatings formed at different thermal spraying and laser cladding conditions were character-ized by means of X-ray diffraction and electron probe microanalysis.The thermal oxidation properties of themixed powders composed of different content of SiC particulates and relevant Ni-based alloy as the balancewere examined using differential scanning calorimetry.The hardness profile of the thermal sprayed and lasercladding coatings was investigated as well.It was found that SiO2particulates were generated and dissolvedand dispersed during the melting and solidification of the laser cladding process,which was ascribed to theoxidation of the dispersed SiC particulates.The micro-hardness depth profile of the target laser claddingcomposite coating was characterized by gradient distribution,which could be related to the gradient distribu-tion of the hard SiC and SiO2particulates in the dendrites and interdendrites of the cladding layer.Both SiCand SiO2particulates contributed to greatly increasing the microhardness and mechanical properties of the ti-tled laser cladding composite coatings.

Ti-based composite coatings with gradient TiC_x reinforcements on TC4 titanium alloy prepared by laser cladding

TiCx-NiTi2/Ti cermet composite coatings C1 and C2 with gradient TiCx reinforcements were prepared on TC4 titanium alloy by laser cladding method.The microstructure and phase compositions were analyzed by means of scanning electron microscopy(SEM),energy-dispersive spectroscopy(EDS)and X-ray diffraction(XRD)meter.The TiCx exhibited a dendritic microstructure,and homogeneously dispersed in the Ti-based matrix where NiTi2 was embedded.With increasing ingredient supercooling,temperature gradient and cooling temperature,the dendrites displayed a finer morphology with longer primary trunks and intensified side branches in the dilution zone.But the smoothed,coarse columnar ones became dominant in the upper clad layer due to the repeated energy input during multi-track cladding.The Vickers microhardness presented a linear change trend through the cross-sections,which well confirmed the gradient distribution of TiCx.With more TiCx,C1 presented higher hardness than C2.

Mechanism of Zr in in situ-synthesized particle reinforced composite coatings by laser cladding

By adding mixture of ZrOand carbon, a Zrenhanced composite coating was produced onto an AISI1045 substrate by laser cladding. The microstructure and phase formation, microhardness and wear resistance of the composite coating were studied. The experimental results indicate that the composite coating with metallurgical bonding to substrate consists of y-Ni, massive ceramic particles of ZrC,NiZr, NiZr,(Fe,Ni)Cand FeC. The in situ-synthesized ZrC particles are uniformly dispersed in composite coating, which refines the microstructure of composite coating. With different Zr02 and carbon additions, the properties are improved differently. Finally, the fine in situ ZrC particles improve the microhardness of composite coating to HV650, which is nearly 2.7 times that of Ni25 coating. Also, the composite coating has an advantage in wear resistance; it offers better wear resistance when more mixture of ZrOand carbon was added in nickel alloys.

Fabrication of barium-strontium aluminosilicate coatings on C/SiC composites via laser cladding

Barium-strontium aluminosilicate （BSAS） and Si/BSAS coatings were fabricated on the surface of C/SiC composites via a two-step laser cladding process. The microstructure, mechanical properties, and the water vapor corrosion behavior of the samples were investigated. The BSAS coating was found to be tightly bonded to the substrate and only a few pores and microcracks were observed. The introduction of a silicon middle layer was revealed to reduce thermal stress and promote the healing of defects formed during the laser cladding process. To evaluate the corrosion resistance, the BSAS and Si/BSAS-coated C/SiC com- posites were exposed to an atmosphere of 50% H2O and 50% O2 at 1250 ℃. The resulting weight change and flexural strength were measured as a function of the corrosion time. The addition of the silicon middle layer below the BSAS top layer resulted in a better resistance to water vapor corrosion. Furthermore, the Si/BSAS-coated samples showed a lower weight loss and a smaller reduction in flexural strength than the BSAS-coated and the uncoated samples during water vapor corrosion. Thus, laser cladding is dem- onstrated to be an effective and feasible method to fabricate high-quality ceramic coatings on C/SiC composites. The introduction of a silicon middle layer can inhibit defect formation during the laser clad- ding process and protect the composite from water vapor corrosion.

Cyclic oxidation behavior of NiCoCrAlY/YSZ@Ni composite coatings fabricated by laser cladding

Composite coating on GH4169 alloy is prepared by laser cladding yttria-stabilized zirconia(YSZ)@Ni core-shell powdersmixed with NiCoCrAlY alloy powders.The cyclic oxidation behavior of the coatings,especially the growth process of theoxide layer,is investigated based on experimental research and first-principle calculations.The results indicate that theoxidation resistance of coated GH4169 alloy is beer than that of uncoated GH4169 alloy.The coating has three layers:acellular dendrite outer layer,a planar YSZ interlayer,and an inner layer composed of Cr2O3 formed during laser clading.After oxidation at 1000 and 1050℃,as the oxidation time increases,the cellular dendrite outer layer becomes thicker,andthe planar yttria-stabilized zirconia interlayer becomes thinner.Between the planar interlayer and Cr2O3 inner layer,and Al2O3 layer formed.Notably,cracks formed in the intcrface of Al2O3/Cr2O3 owing to thcir weak interface strength,whichled to the failure of the composite coating.

Microstructure and formation mechanism of titanium matrix composites coating on Ti-6Al-4V by laser cladding

Titanium matrix composite coatings were fabricated on Ti-6A1-4V substrate by laser cladding using powder mixtures of Ti+Cr3C2 and Ti+TiB2, respectively. The chemical compositions and mi-crostructures of the coatings were analyzed using scanning electron microscope (SEM), energy dispersive spectrometer (EDS) and X-ray diffraction (XRD). Microhardness was measured by a microhardness tester. The results showed that Cr3C2 particles were dissolved and deposited to form dendritic TiC in the upper section and spherical grain TiC in the bottom of Cr3C2+Ti coating. Most of TiB2 was dissolved in the molten pool by laser irradiation, then formed TiB with fine needles and coarse needles in the TiB2+Ti coating. A few quasi-melted TiB2 particles with irregular shape at the bottom of the coating were observed. The average microhardnesses were approximately HV850-V1000, HV800-V1050 in the Cr3C2+Ti and TiB2+Ti coating, respectively, which were 2-3 times higher than that of Ti-6A1-4V substrate.

Microstructural evolution and abrasive resistance of WC7Co ceramic particle-reinforced Ti6Al4V composite coating prepared by pulse laser cladding

WC7Co/Ti6Al4V composite coatings are deposited on the pure Ti substrate by pulse laser cladding(LC).During the laser melting process,the decomposition of WC7Co particles will lead to the evolution of microstructure and phases,which is directly related to the wear resistance and mechanism of composite coating.The microstructural evolution,phase compositions and interface reaction of WC7Co/Ti6Al4V composite coating were examined by scanning electron microscopy,energydispersive spectrum and X-ray diffraction(XRD).The hardness of different structures and abrasive resistance of composite coating were measured.The results show that the typical microstructure of LC WC7Co/Ti6Al4V composite coating can be classified into dissolved WC7Co composite structure and un-dissolved WC7Co structure.According to XRD results,there are Ti solid solution,W,TiC,VC,Co3W3C and secondary W2C in composite coating.The eutectic structure formed by the dissolved WC7Co particles consisted of W,W2C,TiC and P-Ti solid solution.The mean hardness of different structures exhibits a significant gradient distribution in composite coating.A reaction layer composed of TiC,W and W2C is also generated onto the interface between un-dissolved WC7Co particles and Ti6Al4V alloy matrix.The abrasive mechanisms of WC7Co/Ti6Al4V composite coating are mainly adhesive wear and oxidation wear during the dry sliding process.

Effect of Fe content on microstructure and mechanical properties of Cu-Fe-based composite coatings by laser induction hybrid rapid cladding

To select the proper composition and obtain an overall material?microstructure?property relationship for Cu?Fe alloy, theeffect of Fe content on microstructure and properties of Cu?Fe-based composite coatings by laser induction hybrid rapid claddingwas investigated. Microstructure characterization of the composite coatings was tested utilizing SEM, XRD and EDS. Microhardnessmeasurement was executed to evaluate the mechanical properties of the composite coatings. The results show that for low Fe content,the composite coating presents a feature that Fe-rich equiaxed dendrites are embedded in the Cu-rich matrix. With increasing Fecontent, the Fe-rich particles are dispersed in the Cu-rich matrix. With further increasing Fe content, large amounts of Cu-richparticles are homogeneously dispersed in the interdendrite of the Fe-rich matrix. Correspondingly, the average microhardness of thecomposite coatings increases gradually with the increase of Fe content and the microhardness of Cu14.5Fe83Si2C0.5 coating is muchtwice higher than that of the substrate.