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<p>To improve the service life of wind turbine bearing shells, NiCrMoSi alloy coatings were deposited via laser cladding at overlap rates of 30%, 40%, 50%, and 60%. The microstructure, phase composition, microhardness, and wear resistance were systematically characterized using SEM, EDS, XRD, EBSD, microhardness testing, and tribological testing systems. Results indicate that the 30% overlap coating exhibited dark spots, stress concentration, microcracks, and coarse grains, whereas the 50% overlap coating showed high porosity and gas pores. Excessive overlap (60%) induced surface protrusions and cracking. In contrast, the coating fabricated at 40% overlap demonstrated optimal cross-sectional quality, free of apparent defects, featuring a fine equiaxed grain structure (average grain size: 5.07μm) and a microhardness of 685.95 HV. This coating achieved the lowest wear loss (0.1mg), exhibiting wear resistance improvements of 80%, 50%, and 75% relative to the 30%, 50%, and 60% overlap coatings, respectively, accompanied by a relatively smooth worn surface. Consequently, a 40% overlap rate yields NiCrMoSi coatings with the best comprehensive performance. This work significantly optimizes coating properties through process parameter control, providing experimental evidence and technical guidance for extending the service life of wind turbine bearing shells.</p>

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Influence of Overlap Rate on Microstructure and Properties of Laser-Clad Coatings for Wind Turbine Bearing Shells

  • 期刊论文

  • 发表日期：

    2026年5月25日

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  • Yu Fengsheng,
  • Cui Quanwei,
  • Wu Guorui,
  • Wu An,
  • Sun Wenlei

摘要

To improve the service life of wind turbine bearing shells, NiCrMoSi alloy coatings were deposited via laser cladding at overlap rates of 30%, 40%, 50%, and 60%. The microstructure, phase composition, microhardness, and wear resistance were systematically characterized using SEM, EDS, XRD, EBSD, microhardness testing, and tribological testing systems. Results indicate that the 30% overlap coating exhibited dark spots, stress concentration, microcracks, and coarse grains, whereas the 50% overlap coating showed high porosity and gas pores. Excessive overlap (60%) induced surface protrusions and cracking. In contrast, the coating fabricated at 40% overlap demonstrated optimal cross-sectional quality, free of apparent defects, featuring a fine equiaxed grain structure (average grain size: 5.07μm) and a microhardness of 685.95 HV. This coating achieved the lowest wear loss (0.1mg), exhibiting wear resistance improvements of 80%, 50%, and 75% relative to the 30%, 50%, and 60% overlap coatings, respectively, accompanied by a relatively smooth worn surface. Consequently, a 40% overlap rate yields NiCrMoSi coatings with the best comprehensive performance. This work significantly optimizes coating properties through process parameter control, providing experimental evidence and technical guidance for extending the service life of wind turbine bearing shells.