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<p>We propose a combined laser derusting and strengthening process that can effectively remove rust and corrosion stains from component surfaces while enhancing their mechanical properties. This study investigates the flow behavior and morphological evolution of the molten pool during laser derusting and strengthening of 42CrMo steel, establishing a simulation model that closely matches the original surface topography. A three-dimensional finite element analysis was conducted to simulate the sample surface under different laser power settings. The simulation results were compared with experimental data, demonstrating that the molten pool flow model can effectively predict both the molten pool dynamics and the micro-scale surface fluctuations of 42CrMo steel. The predicted surface roughness and molten pool depth from the simulation exhibited a fitting error of less than 10% compared to experimental measurements. By adjusting the laser power, surface cleaning was achieved while simultaneously improving surface finish. After laser treatment, the surface roughness (Ra) of 42CrMo steel was reduced to 0.54&#xa0;μm, and its hardness significantly increased to over 640 HV0.1, demonstrating notable composite strengthening effects.</p>

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Numerical Simulation and Experimental Study of Laser Rust Removal and Composite Strengthening of 42CrMo Steel

  • 期刊论文

  • 发表日期：

    2026年3月6日

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  • ChangE Huang,
  • Jiaxin Yang,
  • Xinkai Li,
  • Rongwei Lu,
  • Xulong Ren,
  • Zhenzhao Mo,
  • Ming Qiu

摘要

We propose a combined laser derusting and strengthening process that can effectively remove rust and corrosion stains from component surfaces while enhancing their mechanical properties. This study investigates the flow behavior and morphological evolution of the molten pool during laser derusting and strengthening of 42CrMo steel, establishing a simulation model that closely matches the original surface topography. A three-dimensional finite element analysis was conducted to simulate the sample surface under different laser power settings. The simulation results were compared with experimental data, demonstrating that the molten pool flow model can effectively predict both the molten pool dynamics and the micro-scale surface fluctuations of 42CrMo steel. The predicted surface roughness and molten pool depth from the simulation exhibited a fitting error of less than 10% compared to experimental measurements. By adjusting the laser power, surface cleaning was achieved while simultaneously improving surface finish. After laser treatment, the surface roughness (Ra) of 42CrMo steel was reduced to 0.54 μm, and its hardness significantly increased to over 640 HV0.1, demonstrating notable composite strengthening effects.