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Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method

Zilin HUANG,Gang WANG,Shaopeng WEI,Changhong LI,Yiming RONG

《机械工程前沿（英文）》 2016年第11卷第3期页码 242-249 doi: 10.1007/s11465-016-0397-7

摘要：

Laser hot wire cladding, with the prominent features of low heat input, high energy efficiency, and high precision, is widely used for remanufacturing metal parts. The cladding process, however, needs to be improved by using a quantitative method. In this work, volumetric defect ratio was proposed as the criterion to describe the integrity of forming quality for cladding layers. Laser deposition experiments with FV520B, one of martensitic stainless steels, were designed by using the Taguchi method. Four process variables, namely, laser power (P), scanning speed (V_s), wire feed rate (V_f), and wire current (I), were optimized based on the analysis of signal-to-noise (S/N) ratio. Metallurgic observation of cladding layer was conducted to compare the forming quality and to validate the analysis method. A stable and continuous process with the optimum parameter combination produced uniform microstructure with minimal defects and cracks, which resulted in a good metallurgical bonding interface.

关键词： process optimization Taguchi method signal-to-noise (S/N) ratio volumetric defect ratio laser hot wire cladding

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Hybrid forming mechanism of patternless casting and laser cladding

Zhongde SHAN, Fuzhen SUN, Yang LIU

《机械工程前沿（英文）》 2019年第14卷第4期页码 393-401 doi: 10.1007/s11465-019-0550-1

摘要： In accordance with the requirement of manufacturing dies quickly and economically, a hybrid forming method of stamping dies for automobile panels is proposed. The method combines digital patternless casting and high-power laser cladding. An experimental study is conducted on the hybrid forming process and its trial production and application in the manufacturing of stamping dies for typical panels. Results prove that the laser cladding layer exceeds HRC60 (Rockwell hardness) and thus meets the production efficiency requirement of automobile dies. The rate of defects is well controlled. Compared with traditional technology, this technology has remarkable advantages and advancement.

关键词： patternless casting laser cladding hybrid forming rapid tooling

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激光表面改性技术发展研究

张群莉,王梁,梅雪松,姚建华

《中国工程科学》 2020年第22卷第3期页码 71-77 doi: 10.15302/J-SSCAE-2020.03.010

摘要：

激光表面改性技术利用高能量密度的激光束对零部件局部易损易耗区域进行快速处理，获得材料表面所需性能，进而大幅延长零部件使用寿命，已在航空航天、石油化工、能源、交通、冶金等领域获得应用。本文针对激光冲击强化、激光淬火、激光熔覆3 种典型的激光表面改性技术，梳理了相应技术特点及国内外应用现状，凝练我国相关技术领域面临的差距与问题，总结激光表面改性技术的重点发展方向：专用合金材料制备、多能场激光复合表面改性、面向现场的激光再制造、激光冲击强化控形控性、激光表面改性智能化、激光表面微结构化。从政府引导、国产化创新、产业链完善、质量评价标准体系、人才培养等方面提出发展建议，以期为我国激光表面改性技术发展提供参考借鉴。

关键词：激光表面改性冲击强化淬火熔覆发展趋势

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The Application and the Prospect of Remanufacturing Technologies in the Metallurgical Industry

Jie Xiong,Jian-cheng Fan,Jv Yuan

《工程管理前沿（英文）》 2016年第3卷第2期页码 165-170 doi: 10.15302/J-FEM-2016023

摘要： Metallurgical equipment is subjected to severe working conditions and the components suffer from various types of physical damages such as abrasion, corrosion and crack. Advanced surface engineering technologies and resistant coatings on the damaged surface can improve surface properties, extend service lives, reduce maintenance costs and improve product quality in the metallurgical industry. This paper introduces remanufacturing technologies, including electroplating, overlaying welding, thermal spraying and laser surface cladding and their applications in the metallurgical industry, and analyzes the development tendency and prospect of remanufacturing technologies.

关键词： remanufacturing technology electroplating overlaying welding thermal spraying laser surface cladding

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激光熔覆NiCrAl-陶瓷涂层的显微组织研究

陈庆华,魏仑,龙晋明,李俊昌

《中国工程科学》 2001年第3卷第10期页码 64-71

摘要：

运用激光熔覆技术在40Cr钢表面制备了(TiO₂+B₂O₃+Al₂O₃+TiB₂)/NiCrAl金属陶瓷涂层，其中的TiB₂和Al₂O₃陶瓷颗粒在激光加工过程中原位反应生成；对熔覆层的组织、物相、元素分布和显微硬度分布特征进行了分析研究；熔覆层中的主相依次分别是γ-Ni,γ′,Al₂O₃和TiB₂，熔覆层的微观结构和硬度主要和激光处理参数和熔覆层化学组成有关^［1～9］；陶瓷相的原位生成和加入，大大改善了熔覆层的硬度和覆层/基体界面的结合性能。

关键词：激光熔覆金属陶瓷微观组织物相显微硬度

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Influence of the field humiture environment on the mechanical properties of 316L stainless steel repaired with Fe314

Lianzhong ZHANG, Dichen LI, Shenping YAN, Ruidong XIE, Hongliang QU

《机械工程前沿（英文）》 2018年第13卷第4期页码 513-519 doi: 10.1007/s11465-018-0503-0

摘要：

The mechanical properties of 316L stainless steel repaired with Fe314 under different temperatures and humidities without inert gas protection were studied. Results indicated favorable compatibility between Fe314 and 316L stainless steel. The average yield strength, tensile strength, and sectional contraction percentage were higher in repaired samples than in 316L stainless steel, whereas the elongation rate was slightly lower. The different conditions of humiture environment on the repair sample exerted minimal influence on tensile and yield strengths. The Fe314 cladding layer was mainly composed of equiaxed grains and mixed with randomly oriented columnar crystal and tiny pores or impurities in the tissue. Results indicated that the hardness value of Fe314 cladding layer under different humiture environments ranged within 419–451.1 HV_0.2. The field humiture environment also showed minimal impact on the average hardness of Fe314 cladding layers. Furthermore, 316L stainless steel can be repaired through laser cladding by using Fe314 powder without inert gas protection under different temperatures and humidity environments.

关键词： laser cladding repaired performance tensile strength temperature and humidity environment

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Construction of nitrogen-doped carbon cladding LiMnO film electrode with enhanced stability for electrochemically

《化学科学与工程前沿（英文）》 2023年第17卷第12期页码 2050-2060 doi: 10.1007/s11705-023-2343-7

摘要： Reducing the dissolution of Mn from LiMn₂O₄ (LMO) and enhancing the stability of film electrodes are critical and challenging for Li⁺ ions selective extraction via electrochemically switched ion exchange technology. In this work, we prepared a nitrogen-doped carbon cladding LMO (C-N@LMO) by polymerization of polypyrrole and high-temperature annealing in the N₂ gas to achieve the above purpose. The modified C-N@LMO film electrode exhibited lower Mn dissolution and better cyclic stability than the LMO film electrode. The dissolution ratio of Mn from the C-N@LMO film electrode decreased by 42% compared to the LMO film electrode after 10 cycles. The cladding layer not only acted as a protective layer but also functioned as a conductive shell, accelerating the migration rate of Li⁺ ions. The intercalation equilibrium time of the C-N@LMO film electrode reached within an hour during the extraction of Li⁺ ions, which was 33% less compared to the pure LMO film electrode. Meanwhile, the C-N@LMO film electrode retained evident selectivity toward Li⁺ ions, and the separation factor was 118.38 for Li⁺ toward Mg²⁺ in simulated brine. Therefore, the C-N@LMO film electrode would be a promising candidate for the recovery of Li⁺ ions from salt lakes.

关键词： LiMn₂O₄ lithium extraction surface coating cyclic stability Mn dissolution

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Steady-state thermal-hydraulic analysis of SCWR assembly

LIU Xiaojing, CHENG Xu

《能源前沿（英文）》 2008年第2卷第4期页码 475-478 doi: 10.1007/s11708-008-0093-3

摘要： Among the six gen-IV reactor concepts recommended by the gen-IV international forum (GIF), supercritical water-cooled reactor (SCWR), the only reactor with water as coolant, achieves a high thermal efficiency and, subsequently, has economic advantages over the existing reactors due to its high outlet temperature. A thermal-hydraulic analysis of the SCWR assembly is performed in this paper using the modified COBRA-IV code. Two approaches to reduce the hot channel factor are investigated: decreasing the moderator mass flow and increasing the thermal resistance between moderator channel and its adjacent sub-channels. It is shown that heat transfer deterioration cannot be avoided in SCWR fuel assembly. It is, therefore, highly required to calculate the cladding temperature accurately and to preserve the fuel rod cladding integrity under heat transfer deterioration conditions.

关键词： cladding temperature assembly temperature coolant resistance

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激光去除与连接技术发展研究

陈俐,巩水利,何恩光

《中国工程科学》 2020年第22卷第3期页码 78-84 doi: 10.15302/J-SSCAE-2020.03.012

摘要：

随着激光技术的发展，激光去除与连接技术深刻影响着制造业技术的发展，并以柔性、高效、高质的综合优势成为不可或缺的先进制造技术。在先进制造智能化发展的时代，激光技术、数字信息技术等的融合必将推动激光去除与连接技术的应用发展与创新。本文选取工业应用最广的激光焊接、激光切割、激光打孔、激光打标4 种激光去除与连接技术，概述了激光去除与连接技术的应用现状，分析了其在支撑先进制造发展过程中存在的问题。研究表明，激光去除与连接技术的发展应注重工艺基础和装备研究一体化的研究，解决激光加工单元部件、激光加工工艺、智能集成各环节的关键技术，强化工艺基础研究平台建设，关注技术创新和人才培养的多维度结合，以促进激光去除与连接技术从工艺应用开发到装备市场保障的生态链式的协同发展。

关键词：激光加工激光焊接激光切割激光打孔激光打标

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Temperature field simulation of laser homogenizing equipment

Juanjuan WANG, Yunshan WANG, Fudong ZHU

《机械工程前沿（英文）》 2009年第4卷第1期页码 49-52 doi: 10.1007/s11465-009-0005-1

摘要： The laser homogenizing equipment was devised using the ring scanning principle. Its working principle is explained. A laser scanning ring facula is obtained when the laser beam goes through the equipment’s optical system rotating with high-frequency. The scanning ring facula’s mathematic model is established based on the temperature field’s superposing principle. The ring facula’s light intensity distribution and temperature distribution characteristics are achieved by simulating its temperature field. By studying the effect of parameters on the temperature field, the best parameter can be found. Results show that favorable temperature distribution characteristics can be attained by choosing appropriate parameters, and even the thermal effect can be realized by utilizing the circumference power compensating for the heat exchange lost in the horizontal direction. The uniform hardness layer and better process quality can be attained using the ring facula optimized for metal laser heat treatment.

关键词： laser homogenizing technology laser scanning ring facula temperature field

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我国激光技术与应用2035 发展战略研究

“我国激光技术与应用2035 发展战略研究”项目综合组

《中国工程科学》 2020年第22卷第3期页码 1-6 doi: 10.15302/J-SSCAE-2020.03.001

摘要：

为促进激光技术及应用的发展，中国工程院于2018 年启动了“我国激光技术与应用2035 发展战略研究”重点咨询项目，本文是项目研究综合报告，文章简要分析了激光技术及在科研与产业中的工具性、引领性和颠覆性作用，分析了我国激光技术在前沿激光、制造加工、信息通信、医疗诊治等领域的科研和应用的发展现状，梳理了多个制约加速发展的问题，提出了我国激光技术及应用2035 年发展目标设想：强化顶层统筹谋划，引领我国激光技术与应用产业快速发展；加强基础研究，聚力突破产业化发展中的重大基础问题、共性技术基础和基础材料、器件；设立应用研发专项，打造多个新激光产业链；创新产业协同机制，完善激光产业创新生态；强化激光基础教育，加大对激光及光学学科人才培养力度等政策措施建议。

关键词：激光技术激光制造激光通信激光诊疗

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Processing parameter optimization of fiber laser beam welding using an ensemble of metamodels and MOABC

《机械工程前沿（英文）》 2022年第17卷第4期 doi: 10.1007/s11465-022-0703-5

摘要： In fiber laser beam welding (LBW), the selection of optimal processing parameters is challenging and plays a key role in improving the bead geometry and welding quality. This study proposes a multi-objective optimization framework by combining an ensemble of metamodels (EMs) with the multi-objective artificial bee colony algorithm (MOABC) to identify the optimal welding parameters. An inverse proportional weighting method that considers the leave-one-out prediction error is presented to construct EM, which incorporates the competitive strengths of three metamodels. EM constructs the correlation between processing parameters (laser power, welding speed, and distance defocus) and bead geometries (bead width, depth of penetration, neck width, and neck depth) with average errors of 10.95%, 7.04%, 7.63%, and 8.62%, respectively. On the basis of EM, MOABC is employed to approximate the Pareto front, and verification experiments show that the relative errors are less than 14.67%. Furthermore, the main effect and the interaction effect of processing parameters on bead geometries are studied. Results demonstrate that the proposed EM-MOABC is effective in guiding actual fiber LBW applications.

关键词： laser beam welding parameter optimization metamodel multi-objective

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Development of lunar regolith composite and structure via laser-assisted sintering

《机械工程前沿（英文）》 doi: 10.1007/s11465-021-0662-2

摘要： Aiming at the exploration and resource utilization activities on the Moon, in situ resource utilization and in situ manufacturing are proposed to minimize the dependence on the ground transportation supplies. In this paper, a laser-assisted additive manufacturing process is developed to fabricate lunar regolith composites with PA12/SiO₂ mixing powders. The process parameters and composite material compositions are optimized in an appropriate range through orthogonal experiments to establish the relationship of process–structure–property for lunar regolith composites. The optimal combination of composite material compositions and process parameters are mixing ratio of 50/50 in volume, laser power of 30 W, scanning speed of 3500 mm/s, and scanning hatch space of 0.2 mm. The maximum tensile strength of lunar regolith composites reaches 9.248 MPa, and the maximum depth of surface variation is 120.79 μm, which indicates poor powder fusion and sintering quality. Thereafter, the mechanical properties of laser-sintered lunar regolith composites are implemented to the topology optimization design of complex structures. The effectiveness and the feasibility of this laser-assisted process are potentially developed for future lightweight design and manufacturing of the solar panel installed on the lunar rover.

关键词： in situ manufacturing laser-assisted powder fusion process mechanical properties topological structure design

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Advances in polishing of internal structures on parts made by laser-based powder bed fusion

《机械工程前沿（英文）》 2023年第18卷第1期 doi: 10.1007/s11465-022-0724-0

摘要： The internal structures of metallic products are important in realizing functional applications. Considering the manufacturing of inner structures, laser-based powder bed fusion (L-PBF) is an attractive approach because its layering principle enables the fabrication of parts with customized interior structures. However, the inferior surface quality of L-PBF components hinders its productization progress seriously. In this article, process, basic forms, and applications relevant to L-PBF internal structures are reviewed comprehensively. The causes of poor surface quality and differences in the microstructure and property of the surface features of L-PBF inner structures are presented to provide a perspective of their surface characteristics. Various polishing technologies for L-PBF components with inner structures are presented, whereas their strengths and weaknesses are summarized along with a discussion on the challenges and prospects for improving the interior surface quality of L-PBF parts.

关键词： laser-based powder bed fusion polishing internal structures surface quality surface features post process additive manufacturing

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zone-layered trimming method for ceramic core of aero-engine blade based on an advanced reconfigurable laser

《机械工程前沿（英文）》 2022年第17卷第2期 doi: 10.1007/s11465-022-0675-5

摘要： Ceramic structural parts are one of the most widely utilized structural parts in the industry. However, they usually contain defects following the pressing process, such as burrs. Therefore, additional trimming is usually required, despite the deformation challenges and difficulty in positioning. This paper proposes an ultrafast laser processing system for trimming complex ceramic structural parts. Opto-electromechanical cooperative control software is developed to control the laser processing system. The trimming problem of the ceramic cores used in aero engines is studied. The regional registration method is introduced based on the iterative closest point algorithm to register the path extracted from the computer-aided design model with the deformed ceramic core. A zonal and layering processing method for three-dimensional contours on complex surfaces is proposed to generate the working data of high-speed scanning galvanometer and the computer numerical control machine tool, respectively. The results show that the laser system and the method proposed in this paper are suitable for trimming complex non-datum parts such as ceramic cores. Compared with the results of manual trimming, the method proposed in this paper has higher accuracy, efficiency, and yield. The method mentioned above has been used in practical application with satisfactory results.

关键词： ceramic parts trimming computer-aided laser manufacturing 3D vision reconfigurable laser processing system