Residual Stress Analysis and Shape Optimization of Laser Cladded Ni-Based Alloy Coatings

Lunxiang Li; Deqiang Zhang; Jinhua Li; Wenqiang Sun

doi:10.3788/LOP57.171405

Journals >Laser & Optoelectronics Progress >Volume 57 >Issue 17 >Page 171405 > Article

Laser & Optoelectronics Progress
Vol. 57, Issue 17, 171405 (2020)

Residual Stress Analysis and Shape Optimization of Laser Cladded Ni-Based Alloy Coatings

Lunxiang Li^1、*, Deqiang Zhang¹, Jinhua Li¹, and Wenqiang Sun²

Author Affiliations

¹Faculty of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, Liaoning 121001, China

²Engineering Training Center, Liaoning University of Technology, Jinzhou, Liaoning 121001, China

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DOI: 10.3788/LOP57.171405 Cite this Article Set citation alerts

Lunxiang Li, Deqiang Zhang, Jinhua Li, Wenqiang Sun. Residual Stress Analysis and Shape Optimization of Laser Cladded Ni-Based Alloy Coatings[J]. Laser & Optoelectronics Progress, 2020, 57(17): 171405 Copy Citation Text

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Fig. 1. Schematic of longitudinal section of cladding layer

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Fig. 2. Test results

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Fig. 3. Geometric model

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Fig. 4. Meshing effect

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Fig. 5. Cross-sectional morphology of molten pool

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Fig. 9. Sectional morphology of cladding layer

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Fig. 10. Schematic of path location

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Fig. 11. Residual stress distributions on two paths. (a) path 1; (b) path 2

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Element	C	Si	Mn	P	S	Cr	Ni	Fe
Value	0.420-0.500	0.170-0.370	0.500-0.800	≤0.035	≤0.035	≤0.250	≤0.280	Bal.

Table 1. Chemical compositions of 45 steel (mass fraction, %)

Element	C	Cr	Si	W	Fe	B	Ni
Value	0.80	15.50	4.00	3.00	15.00	3.50	Bal.

Table 2. Chemical compositions of Ni60 powder (mass fraction, %)

Variable	Notation	Unit	Value
Variable	Notation	Unit	Level -2	Level -1	Level 0	Level 1	Level 2
Laser power	LP	W	1200	1300	1400	1500	1600
Scanning speed	SS	mm·s^-1	4.0	4.5	5.0	5.5	6.0
Power feeding voltage	PFV	V	7.0	7.5	8.0	8.5	9.0
Defocusing amount	DA	mm	13	14	15	16	17

Table 3. Cladding parameters and levels

Power feeding voltage /V	7	8	9	10	11	12	13	14	15	16	17	18	19	20
Powder feeding rate /(g·min^-1)	6	7	9	10	11	13	16	17	18	21	22	24	24	25

Table 4. Relationship between powder feeding voltage and powder feeding rate

ExperimentNo.	Laserpower /W	Scanning speed /( mm·s^-1)	Power feedingvoltage /V	Defocusingamount /mm	Width-heightratio	Dilutionrate /%
1	1500	5.5	7.5	14	6.92	40.16
2	1300	4.5	8.5	14	2.87	26.85
3	1300	4.5	7.5	14	3.87	31.06
4	1200	5.0	8.0	15	7.10	34.36
5	1300	5.5	7.5	14	6.50	41.58
6	1400	5.0	8.0	13	3.98	34.80
7	1600	5.0	8.0	15	6.78	48.00
8	1400	6.0	8.0	15	9.95	47.57
9	1500	4.5	7.5	14	4.30	43.13
10	1400	5.0	8.0	15	6.67	46.20
11	1500	5.5	8.5	16	9.36	51.53
12	1400	5.0	8.0	15	7.31	50.29
13	1300	4.5	7.5	16	8.21	41.13
14	1400	5.0	7.0	15	9.88	49.81
15	1400	5.0	8.0	17	10.42	54.16
16	1500	4.5	8.5	16	7.16	51.38
17	1300	5.5	7.5	16	11.43	46.25
18	1400	5.0	9.0	15	8.23	44.48
19	1400	5.0	8.0	15	7.01	48.93
20	1300	5.5	8.5	14	5.35	35.94
21	1500	4.5	8.5	14	3.20	35.80
22	1300	4.5	8.5	16	6.26	41.75
23	1500	5.5	7.5	16	10.47	51.91
24	1500	4.5	7.5	16	8.99	54.65
25	1500	5.5	8.5	14	5.96	37.44
26	1400	5.0	8.0	15	6.22	51.98
27	1400	4.0	8.0	15	3.17	40.67
28	1400	5.0	8.0	15	5.89	47.71
29	1300	5.5	8.5	16	8.25	44.64
30	1400	5.0	8.0	15	5.50	49.90

Table 5. Central composite design and results

Source	Sum of squares	Mean square	F-value	P-value	Reliability
Model	144.77	36.19	84.13	<0.0001	Significant
S	45.21	45.21	105.09	<0.0001
V	10.11	10.11	23.51	<0.0001
D	80.81	80.81	187.86	<0.0001
V²	8.64	8.64	20.08	0.0001
Residual	10.75	0.43
Lack-of-fit value	8.39	0.43	0.88	0.6232	Not significant
Pure error	2.37	0.47
Total	155.53
R²=0.9309			$R_{PRED}^{2}$ =0.8861
$R_{ADJ}^{2}$ =0.9198			Signal-to-noise ratio: 30.154

Table 6. Variance analysis of width-height ratio

Source	Sum of squares	Mean square	F-value	P-value	Reliability
Model	1424.73	129.52	31.34	<0.0001	Significant
P	294.56	294.56	71.72	<0.0001
S	58.59	58.59	14.18	0.0014
V	51.63	51.63	12.49	0.0024
D	704.17	704.17	170.39	<0.0001
P×S	62.17	62.17	15.04	0.0011
P×D	13.32	13.32	3.22	0.0894
V×D	14.55	14.55	3.52	0.0769
P²	149.63	149.63	36.20	<0.0001
S²	70.27	70.27	17.00	0.0006
V²	19.56	19.56	4.73	0.0432
D²	62.59	62.59	15.15	0.0011
Residual	74.39	4.13
Lack-of-fit value	50.37	4.13	1.00	0.5456	Not significant
Pure error	20.69	4.14
Total	1499.12
R²=0.9504			$R_{PRED}^{2}$ =0.8462
$R_{ADJ}^{2}$ =0.9201			Signal-to-noise ratio: 19.478

Table 7. Variance analysis of dilution rate

Parameter	Criterion	Limit
Parameter	Criterion	Low	Upper
Laser power	In range	1200 W	1600 W
Scanning speed	In range	1 mm·s^-1	3 mm·s^-1
Powder feeding voltage	In range	7 V	9 V
Defocusing amount	In range	13 mm	17 mm
W/H	In range	3	6
η	In range	30%	40%

Table 8. Optimization criteria

Parameter	Predicted result of model 1	Predicted result of model 2	Predicted result of model 3	Actual result
LP /W	1286.99	1281.53	1338	1290
SS /(mm·s^-1)	3.73	3.87	3.44	3.70
PFV /V	8.32	8.23	7.38	8.30
DA /mm	14.45	14.23	13.82	14.50
W /H	4.508	4.506	4.419	4.800
η /%	35.125	35.165	35.135	38.000
Desirability of model	0.863	0.861	0.830

Table 9. Optimization results and validation

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