The physical phenomena, calculations of thermal processes, and technological know-how of the authors on methods of laser surface engineering are presented: increasing the rigidity of thin-sheet metal products; forming sheet metal products; thermo-deformation strengthening of metal products; hardening of cutting tools; thermal cycling of plasma coatings; laser thermal deformation synthesis of diamond-containing composite coatings; laser powder cladding of wear-resistant coatings; laser casting and projection casting technologies for the production of bimetals. To increase the rigidity of thin-sheet metal products, laser forming of structural stiffening ribs is proposed, which consists in directed linear melting of the surface of a thin-sheet product and the occurrence of two effects: the effect of compensation of working stresses due to the formation of residual stresses equal in magnitude and opposite in sign to the maximum working stresses; the effect of reinforcement due to the creation of a pattern of local areas with increased strength and hardness as a result of structural and phase transformations. Based on calculations of the stress–strain state of a thin-sheet disc under various loading conditions, optimal shapes of structural stiffening ribs have been developed. The mechanisms of longitudinal and transverse bending of the sheet during laser processing are considered. Directions for preventing warping during laser processing of thin-sheet parts are proposed by means of: double-sided laser processing; multi-pass laser processing; ensuring a rectangular HAZ shape. Technological solutions for ensuring a rectangular HAZ shape are provided. The mechanisms of laser forming of sheet products are analyzed: temperature gradient, bulging, and polymorphic transformations. Based on calculations of temperature fields and deformations and experimental studies of the influence of the number of passes, the diameter of the focusing spot, and the speed of the laser beam, comprehensive parameters are proposed that ensure controlled laser forming. The features of laser forming of unhardened and pre-hardened carbon steels are analyzed. Technological schemes for combined laser thermal deformation strengthening are proposed, which consists of combining laser ultra-fast local heating of metals with mechanical plastic deformation by a roller. It has been experimentally proven that high-temperature plastic deformation of the surface layer suppresses the development of recrystallization processes, increases the density and directionality of dislocations, forms branched sub-boundaries, refines grains, increases microhardness and the depth of the hardened layer, and forms compressive residual stresses. Based on the range of favorable temperatures, the optimal distance for applying the deforming load and the force that ensures guaranteed plastic deformation have been determined. Examples of industrial applications of laser thermal deformation strengthening are provided. The adequacy of the mathematical model of the heat transfer process during the strengthening of blade-shaped elements (cutting tools) with a laser beam has been developed and experimentally verified. The influence of the following parameters on the temperature field of the blade has been analyzed: laser beam speed, distance between the laser beam axis and the cutting edge, heating spot radius, and blade sharpening angle. The types of defects and the limiting conditions for their formation have been determined. Based on the analysis of critical values of the laser processing mode, a diagram of the range of technological modes of guaranteed quality of cutting tools was developed using CT80 steel as an example. The scientific and technological principles of combined plasma-laser coating are considered. It consists of two sequential processes: plasma spraying for controlled surface doping and subsequent laser thermal cycling to distribute the alloying elements in depth and ensure a favorable microstructure and mechanical properties of the surface layer. A mechanism of laser thermal cycling has been proposed, which consists in the occurrence of a thermal shock during ultra-fast heating and excitation of an elastic wave, followed by tunneling of the alloying elements, grain refinement, and recrystallization in the deeper layers of the metal. Based on calculations of the temperature field of a moving laser beam in a two-layer medium and studies of mass transfer of alloying elements and changes in the mechanical properties of the surface layer, technological recommendations for laser thermal cycling of plasma coatings have been developed. Examples of combined plasma-laser coating application in industry are given. A new technology has been developed for laser thermal deformation synthesis of diamond-containing composite coatings, which includes laser melting of the product surface with simultaneous dosed addition of metal powder binder and artificial diamonds, followed by plastic deformation of the composite layer during cooling to 650–500 °C. Based on studies of the effect of heating temperatures and laser irradiation conditions on the mechanical properties of synthetic and natural diamonds, quality assurance requirements for high-temperature diamond processing have been established. Based on mathematical modeling of laser thermo-deformation synthesis of diamond-implanted composite coatings, optimal technological schemes, laser irradiation parameters, and plastic deformation modes of the composite layer in the production of diamond cutting wheels and tool drums with replaceable cutting inserts with diamond-implanted coatings have been determined. Technological schemes of laser-powder surfacing are considered, which ensure a minimum depth of penetration and a higher proportion of base metal in the deposit compared to electric arc, plasma, and gas surfacing. Based on mathematical modeling of the laser-powder surfacing process, it has been proven that it is possible to control the maximum heating temperature, heating rate, surface layer cooling rate, lifetime, and shape of the surfacing pool by changing the heat flux density distribution function in the focusing zone. It has been substantiated that the optimal distribution of heat flux density is uneven, with the maximum shifted to the edge of the focus spot in the direction of the laser beam. The technological parameters of laser surfacing and the physical and mechanical properties of surfaced layers from nickel-based, iron-based, and boron carbide powders were analyzed. It has been proven that the level and nature of residual stress distribution is determined by two components: the composition of the deposited powder and the nature of the heat flux density distribution of the laser radiation. The mechanisms and factors contributing to crack formation have been analyzed. The optimal parameters of the laser surfacing (power density level, heat flux density distribution, and laser beam travel speed) have been determined, at which the number of cracks is reduced by 2–3 times. Examples of laser surfacing technologies are proposed to increase the service life of fast-rotating parts: gas turbine blades of aircraft engines (by applying a wear-resistant coating to the contact shelves); drill bits (first, by increasing the hardness of the interchangeable bore surface by laser irradiation after normalization and carburizing with quenching, and second, by solid lubrication of the interchangeable bore - cutter friction unit by surfacing with a mixture of bronze and iron powders); diesel engine turbines (by creating a multilayer coating on the working surfaces of the sliding bearing rings). Two laser technologies for producing bimetals have been developed: laser casting and projection casting. Laser casting technology involves melting a rectangular section of the surface layer of the bimetal base to a depth of 30–50 μm with a laser beam, while simultaneously feeding the molten functional component of the bimetal from a foundry induction ladle onto the melted surface. Projection casting technology consists of two operations: forming a macro-relief on the surface of the bimetal base (by laser cutting, milling, or plastic deformation) and pouring the melt of the functional component of the bimetal from a foundry induction ladle over the entire length of the workpiece with a surface macro-relief. Macro-relief can be formed on the surface of the functional component of the bimetal in order to preserve its metallurgical properties (for example, when using heat-resistant alloys). Controlling the configuration of the protrusions allows you to control the temperature distribution, the strength of the bond with the bimetal base, and productivity.

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Technological Processes of Laser Surface Engineering

  • Igor Krivtsun,
  • Leonid Golovko,
  • Serhii Fomichov,
  • Oleksii Kaglyak,
  • Yevgenia Chvertko

摘要

The physical phenomena, calculations of thermal processes, and technological know-how of the authors on methods of laser surface engineering are presented: increasing the rigidity of thin-sheet metal products; forming sheet metal products; thermo-deformation strengthening of metal products; hardening of cutting tools; thermal cycling of plasma coatings; laser thermal deformation synthesis of diamond-containing composite coatings; laser powder cladding of wear-resistant coatings; laser casting and projection casting technologies for the production of bimetals. To increase the rigidity of thin-sheet metal products, laser forming of structural stiffening ribs is proposed, which consists in directed linear melting of the surface of a thin-sheet product and the occurrence of two effects: the effect of compensation of working stresses due to the formation of residual stresses equal in magnitude and opposite in sign to the maximum working stresses; the effect of reinforcement due to the creation of a pattern of local areas with increased strength and hardness as a result of structural and phase transformations. Based on calculations of the stress–strain state of a thin-sheet disc under various loading conditions, optimal shapes of structural stiffening ribs have been developed. The mechanisms of longitudinal and transverse bending of the sheet during laser processing are considered. Directions for preventing warping during laser processing of thin-sheet parts are proposed by means of: double-sided laser processing; multi-pass laser processing; ensuring a rectangular HAZ shape. Technological solutions for ensuring a rectangular HAZ shape are provided. The mechanisms of laser forming of sheet products are analyzed: temperature gradient, bulging, and polymorphic transformations. Based on calculations of temperature fields and deformations and experimental studies of the influence of the number of passes, the diameter of the focusing spot, and the speed of the laser beam, comprehensive parameters are proposed that ensure controlled laser forming. The features of laser forming of unhardened and pre-hardened carbon steels are analyzed. Technological schemes for combined laser thermal deformation strengthening are proposed, which consists of combining laser ultra-fast local heating of metals with mechanical plastic deformation by a roller. It has been experimentally proven that high-temperature plastic deformation of the surface layer suppresses the development of recrystallization processes, increases the density and directionality of dislocations, forms branched sub-boundaries, refines grains, increases microhardness and the depth of the hardened layer, and forms compressive residual stresses. Based on the range of favorable temperatures, the optimal distance for applying the deforming load and the force that ensures guaranteed plastic deformation have been determined. Examples of industrial applications of laser thermal deformation strengthening are provided. The adequacy of the mathematical model of the heat transfer process during the strengthening of blade-shaped elements (cutting tools) with a laser beam has been developed and experimentally verified. The influence of the following parameters on the temperature field of the blade has been analyzed: laser beam speed, distance between the laser beam axis and the cutting edge, heating spot radius, and blade sharpening angle. The types of defects and the limiting conditions for their formation have been determined. Based on the analysis of critical values of the laser processing mode, a diagram of the range of technological modes of guaranteed quality of cutting tools was developed using CT80 steel as an example. The scientific and technological principles of combined plasma-laser coating are considered. It consists of two sequential processes: plasma spraying for controlled surface doping and subsequent laser thermal cycling to distribute the alloying elements in depth and ensure a favorable microstructure and mechanical properties of the surface layer. A mechanism of laser thermal cycling has been proposed, which consists in the occurrence of a thermal shock during ultra-fast heating and excitation of an elastic wave, followed by tunneling of the alloying elements, grain refinement, and recrystallization in the deeper layers of the metal. Based on calculations of the temperature field of a moving laser beam in a two-layer medium and studies of mass transfer of alloying elements and changes in the mechanical properties of the surface layer, technological recommendations for laser thermal cycling of plasma coatings have been developed. Examples of combined plasma-laser coating application in industry are given. A new technology has been developed for laser thermal deformation synthesis of diamond-containing composite coatings, which includes laser melting of the product surface with simultaneous dosed addition of metal powder binder and artificial diamonds, followed by plastic deformation of the composite layer during cooling to 650–500 °C. Based on studies of the effect of heating temperatures and laser irradiation conditions on the mechanical properties of synthetic and natural diamonds, quality assurance requirements for high-temperature diamond processing have been established. Based on mathematical modeling of laser thermo-deformation synthesis of diamond-implanted composite coatings, optimal technological schemes, laser irradiation parameters, and plastic deformation modes of the composite layer in the production of diamond cutting wheels and tool drums with replaceable cutting inserts with diamond-implanted coatings have been determined. Technological schemes of laser-powder surfacing are considered, which ensure a minimum depth of penetration and a higher proportion of base metal in the deposit compared to electric arc, plasma, and gas surfacing. Based on mathematical modeling of the laser-powder surfacing process, it has been proven that it is possible to control the maximum heating temperature, heating rate, surface layer cooling rate, lifetime, and shape of the surfacing pool by changing the heat flux density distribution function in the focusing zone. It has been substantiated that the optimal distribution of heat flux density is uneven, with the maximum shifted to the edge of the focus spot in the direction of the laser beam. The technological parameters of laser surfacing and the physical and mechanical properties of surfaced layers from nickel-based, iron-based, and boron carbide powders were analyzed. It has been proven that the level and nature of residual stress distribution is determined by two components: the composition of the deposited powder and the nature of the heat flux density distribution of the laser radiation. The mechanisms and factors contributing to crack formation have been analyzed. The optimal parameters of the laser surfacing (power density level, heat flux density distribution, and laser beam travel speed) have been determined, at which the number of cracks is reduced by 2–3 times. Examples of laser surfacing technologies are proposed to increase the service life of fast-rotating parts: gas turbine blades of aircraft engines (by applying a wear-resistant coating to the contact shelves); drill bits (first, by increasing the hardness of the interchangeable bore surface by laser irradiation after normalization and carburizing with quenching, and second, by solid lubrication of the interchangeable bore - cutter friction unit by surfacing with a mixture of bronze and iron powders); diesel engine turbines (by creating a multilayer coating on the working surfaces of the sliding bearing rings). Two laser technologies for producing bimetals have been developed: laser casting and projection casting. Laser casting technology involves melting a rectangular section of the surface layer of the bimetal base to a depth of 30–50 μm with a laser beam, while simultaneously feeding the molten functional component of the bimetal from a foundry induction ladle onto the melted surface. Projection casting technology consists of two operations: forming a macro-relief on the surface of the bimetal base (by laser cutting, milling, or plastic deformation) and pouring the melt of the functional component of the bimetal from a foundry induction ladle over the entire length of the workpiece with a surface macro-relief. Macro-relief can be formed on the surface of the functional component of the bimetal in order to preserve its metallurgical properties (for example, when using heat-resistant alloys). Controlling the configuration of the protrusions allows you to control the temperature distribution, the strength of the bond with the bimetal base, and productivity.