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<p>Laser cladding is crucial for enhancing surface properties, yet it faces challenges such as residual stress and microstructural inhomogeneity. Ultrasonic vibration, which promotes grain refinement and enhances mechanical properties, offers a potential solution to these issues. This study explores ultrasonic vibration’s impact on Ti6Al4V alloy cladding on 316L stainless steel via numerical simulation. Ultrasonic vibration significantly raises the substrate temperature, reducing the temperature gradient, while leaving the peak molten pool temperature (approximately 3460&#xa0;K) largely unchanged. Higher amplitudes (up to 24&#xa0;μm) enhance the temperature gradient and solidification rate, promoting rapid cooling and solidification. Mechanistically, ultrasonic vibration induces strong convection and enhanced heat transfer within the molten pool, resulting in fine, uniform grain structures. Residual stress analysis shows a reduction from 1.1 to 0.66&#xa0;GPa and a more uniform stress distribution with ultrasonic vibration. This study’s innovative approach provides a deeper understanding of ultrasonic vibration’s role in optimizing laser cladding parameters, contributing significantly to improved microstructure and mechanical properties of the cladding layer. These findings pave the way for broader applications of ultrasonic vibration-assisted laser cladding in industrial processes, offering potential for enhanced material performance and expanded use in various engineering fields.</p>

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Numerical Simulation of Ultrasonic-Assisted Laser Cladding of Ti6Al4V on 316L Stainless Steel

  • 期刊论文

  • 发表日期：

    2025年3月24日

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  • Zaixin Wu,
  • Xiaopeng Liu,
  • Dehong Guo,
  • Wenkang Wang

摘要

Laser cladding is crucial for enhancing surface properties, yet it faces challenges such as residual stress and microstructural inhomogeneity. Ultrasonic vibration, which promotes grain refinement and enhances mechanical properties, offers a potential solution to these issues. This study explores ultrasonic vibration’s impact on Ti6Al4V alloy cladding on 316L stainless steel via numerical simulation. Ultrasonic vibration significantly raises the substrate temperature, reducing the temperature gradient, while leaving the peak molten pool temperature (approximately 3460 K) largely unchanged. Higher amplitudes (up to 24 μm) enhance the temperature gradient and solidification rate, promoting rapid cooling and solidification. Mechanistically, ultrasonic vibration induces strong convection and enhanced heat transfer within the molten pool, resulting in fine, uniform grain structures. Residual stress analysis shows a reduction from 1.1 to 0.66 GPa and a more uniform stress distribution with ultrasonic vibration. This study’s innovative approach provides a deeper understanding of ultrasonic vibration’s role in optimizing laser cladding parameters, contributing significantly to improved microstructure and mechanical properties of the cladding layer. These findings pave the way for broader applications of ultrasonic vibration-assisted laser cladding in industrial processes, offering potential for enhanced material performance and expanded use in various engineering fields.