A micro-textured tool based on laser micro-cladding in-situ forming and a preparation method and application thereof

Abstract

The present application belongs to the technical field of mechanical cutting tool manufacturing, and particularly relates to a micro-textured tool based on laser micro-cladding in-situ forming, a preparation method and application thereof. Specifically, the present application successfully prepares a multi-layer coated tool with a micro-textured morphology. The tool has the advantages of micro-texture, laser cladding layer and multi-layer coating structure, and has high hardness, good self-lubricating performance, good toughness, strong coating adhesion and small internal stress of the coating, and will not produce defects such as deformation or micro-cracks of the tool substrate material. In the cutting process, the tool can effectively reduce the cutting force and cutting temperature, reduce tool wear and improve tool life, and can be widely applied to dry cutting and cutting of difficult-to-machine materials, and therefore has good practical application value.

Description

Technical Field

[0001] This invention belongs to the field of mechanical cutting tool manufacturing technology, specifically relating to a microtextured tool based on laser micro-cladding in-situ forming, its preparation method, and its application. Background Technology

[0002] The information disclosed in the background section of this invention is intended only to enhance the understanding of the overall background of the invention and is not necessarily to be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.

[0003] Dry cutting of metals has been recognized as a green manufacturing process. Its avoidance of cutting fluid significantly reduces manufacturing costs and effectively minimizes environmental pollution and harm to human health. However, due to the lack of lubrication from cutting fluid, dry cutting tool surfaces experience more severe wear or adhesion. Therefore, in recent years, microtexturing the tool rake face or depositing a soft coating on the rake face has become one of the main ways to reduce friction and wear of dry cutting tools and lower cutting temperatures. Surface texturing is an effective method to improve the friction state of the contact interface and reduce wear. Adding appropriate surface textures to the tool surface can further improve the tool's friction-reducing and wear-resistant properties, increasing tool life. Coated tools have evolved from single-layer to diversified and composite technologies; simultaneously, combining different coating materials for cutting tools results in tool surfaces with both high hardness and good self-lubricating properties, thus significantly improving the performance of coated tools.

[0004] Chinese patent CN 201711013253.2 reports a multilayer soft-coated nanotextured cutting tool based on electrojournaling deposition and its preparation method. It uses a femtosecond laser to create a nanotexture on the tool surface and then sequentially deposits MoS2 and WS2 coatings using electrojournaling technology, thereby reducing friction, cutting force and temperature, and improving tool life during dry cutting. However, the bonding strength of the multilayer coating prepared by this method is still relatively low, resulting in a short tool coating lifespan. Chinese patent CN 201910393087.6 reports a microtextured gradient-coated cutting tool and its preparation method. It first uses laser processing technology to create different microtextures on the tool surface, and then uses ion plating + magnetron sputtering technology to deposit a soft-hard gradient coating. During dry cutting, an effective continuous lubricating film can be formed on the tool surface. However, laser processing of surface textures often involves severe thermal effects, causing localized deformation and microcracks in the tool material. Chinese patent CN 201710541381.8 reports a laser-clad graphene-ceramic self-lubricating coated cutting tool and its preparation method. It uses laser cladding technology to prepare a graphene-Al2O3 or Si3N4-based ceramic composite coating on the rake face. During dry cutting, the tool utilizes the graphene to form a continuous solid lubricating film on the tool surface, thereby achieving the tool's self-lubricating function. Traditional laser cladding for coated cutting tools cannot achieve the fabrication of micron-scale structures on the tool surface due to the large laser spot diameter. Summary of the Invention

[0005] To address the problems existing in the prior art, the present invention aims to provide a microtextured cutting tool based on laser micro-cladding in-situ forming, its preparation method, and its applications. Specifically, the cutting tool prepared by the present invention possesses both high hardness and self-lubricating properties; high bonding strength between the coating and the substrate, and between coatings themselves; and it does not produce defects such as deformation or microcracks in the tool substrate material. During cutting, it can effectively reduce cutting force and cutting temperature, reduce tool wear, and improve tool life. Based on the above research results, the present invention is thus completed.

[0006] To achieve the above-mentioned technical objectives, the technical solution of the present invention is as follows:

[0007] In a first aspect, the present invention provides a microtextured tool based on in-situ laser microcladding forming, the microtextured tool comprising at least a tool substrate, wherein a Ni60 powder layer is deposited on the surface of the tool substrate, and then a microtextured shape is formed in-situ on the surface of the tool substrate on which the Ni60 powder layer is deposited using a laser microcladding method; and then a Ni60+WC powder layer, a Ni60+WC+WS2 (5%) powder layer and a Ni60+WC+WS2 (10%) powder layer are sequentially deposited and clad using a laser microcladding method.

[0008] To prevent uncoated powder from affecting subsequent processing, it is necessary to remove the uncoated powder after each use of laser micro-coating; this can be done by ultrasonic cleaning with ethanol.

[0009] A second aspect of the present invention provides a method for preparing the above-mentioned microtextured tool based on laser microcladding in-situ forming, the method comprising:

[0010] S1. Ni60 powder is uniformly deposited on the pretreated tool substrate surface using electro-jet deposition to obtain a Ni60 transition layer.

[0011] S2. A micro-texture is fabricated in situ on the surface of a tool substrate with a Ni60 transition layer by using a laser micro-cladding method. The powder layer area after laser irradiation will be metallurgically bonded to the substrate, and then the unclad powder will be removed.

[0012] S3. Repeat steps S1-S2 to sequentially deposit and clad the Ni60+WC transition layer, the Ni60+WC+WS2 (5%) cladding layer, and the Ni60+WC+WS2 (10%) cladding layer.

[0013] A third aspect of the present invention provides the application of the above-described microtextured cutting tool in the cutting of difficult-to-machine metal materials.

[0014] The beneficial technical effects of one or more of the above technical solutions are as follows:

[0015] 1) The laser micro-cladding in-situ formed micro-textured tool prepared by the above method combines the advantages of micro-texture, laser cladding layer and multi-layer coating structure, and has high hardness, good self-lubricating performance, good toughness, strong coating adhesion and small coating internal stress.

[0016] 2) The microtexture is formed on the rake face of the tool in one step using laser microcladding technology, which avoids defects such as deformation or microcracks in the tool substrate material. Moreover, the laser spot diameter used in laser microcladding technology is small, which can realize the preparation of microtextures with a size of <30μm, thus improving the surface quality and processing accuracy of the microtexture.

[0017] 3) The above technical solution increases the applicability of the tool and reduces the adhesion of the workpiece material to the tool surface. The tool can be widely used in the cutting of metal materials such as stainless steel, titanium alloy, aluminum alloy, and nickel-based alloy, and therefore has good practical application value and prospects. Attached Figure Description

[0018] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0019] Figure 1 This is a process flow diagram of the preparation process of the laser micro-cladding in-situ forming microtextured tool of the present invention; wherein, A is to deposit a Ni60 powder layer on the surface of the tool substrate using electro-jet deposition technology; B is to process the microtexture in-situ on the surface of the tool substrate with the deposited Ni60 transition layer using laser cladding technology; C is to ultrasonically clean the substrate after laser micro-cladding in alcohol; D is to obtain a tool with a crescent-shaped biomimetic pitcher plant microtexture;

[0020] Figure 2 This is a schematic diagram of the multilayer coated microtextured tool structure of the present invention, wherein: 1 is the tool substrate material, 2 is the Ni60 transition layer, 3 is the Ni60+WC transition layer, 4 is the Ni60+WC+WS2 (5%) cladding layer, 5 is the Ni60+WC+WS2 (10%) cladding layer, and 6 is the microtexture.

[0021] Figure 3 This is a comparison of the friction coefficient curves of the laser micro-cladding in-situ forming micro-textured tool in Embodiment 1 of the present invention and commonly used cemented carbide tools;

[0022] Figure 4 The graph shows the average friction coefficient of the laser micro-cladding in-situ forming micro-textured tool under different speed conditions in Embodiment 2 of the present invention. Detailed Implementation

[0023] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0024] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0025] In a typical embodiment of the present invention, a microtextured tool based on in-situ forming by laser microcladding is provided. The microtextured tool includes at least a tool substrate. A Ni60 powder layer is deposited on the surface of the tool substrate. Then, a microtextured shape is formed in-situ on the surface of the tool substrate with the deposited Ni60 powder layer using laser microcladding. Then, a Ni60+WC powder layer, a Ni60+WC+WS2 (5%) powder layer, and a Ni60+WC+WS2 (10%) powder layer are deposited and clad in sequence using laser microcladding.

[0026] The tool substrate can be high-speed steel or cemented carbide;

[0027] The thickness of each powder layer is 20-50 μm.

[0028] To prevent uncoated powder from affecting subsequent processing, it is necessary to remove the uncoated powder after each use of laser micro-coating; this can be done by ultrasonic cleaning with ethanol.

[0029] In another specific embodiment of the present invention, a method for preparing the above-mentioned microtextured tool based on laser micro-cladding in-situ forming is provided, the method comprising:

[0030] S1. Ni60 powder is uniformly deposited on the pretreated tool substrate surface using electro-jet deposition to obtain a Ni60 transition layer.

[0031] S2. A micro-texture is fabricated in situ on the surface of a tool substrate with a Ni60 transition layer by using a laser micro-cladding method. The powder layer area after laser irradiation will be metallurgically bonded to the substrate, and then the unclad powder will be removed.

[0032] S3. Repeat steps S1-S2 to sequentially deposit and clad the Ni60+WC transition layer, the Ni60+WC+WS2 (5%) cladding layer, and the Ni60+WC+WS2 (10%) cladding layer.

[0033] In step S1, the pretreatment method includes: grinding and polishing the tool substrate, and ultrasonically cleaning it in an alcohol solution for 10-30 minutes (preferably 20 minutes) to remove oil stains;

[0034] The tool substrate can be high-speed steel or cemented carbide;

[0035] In steps S2 and S3, the specific parameters for laser micro-cladding are as follows: 1-2 processing times (preferably 1 time), scanning speed of 10-15 mm / s, laser power of 15-20 W (preferably 18 W), spot diameter of 15-30 μm (preferably 20 μm), and laser frequency of 10-30 kHz (preferably 20 kHz).

[0036] The mass ratio of Ni60 to WC in the Ni60+WC transition layer is 9:1.

[0037] The mass ratio of Ni60, WC, and WS2 in the Ni60+WC+WS2 (5%) cladding layer is 90:5:5;

[0038] The mass ratio of Ni60, WC, and WS2 in the Ni60+WC+WS2 (10%) cladding layer is 85:5:10;

[0039] In another specific embodiment of the present invention, the average particle sizes of Ni60, WC and WS2 are 200 nm, 300 nm and 2 μm, respectively.

[0040] In another specific embodiment of the present invention, the preparation method further includes polishing the tool obtained in step S3 to achieve the desired surface roughness.

[0041] In another specific embodiment of the present invention, the application of the above-mentioned microtextured tool in the cutting and machining of metal materials is provided.

[0042] The metal materials mentioned include, but are not limited to, stainless steel, titanium alloys, aluminum alloys, and nickel-based alloys.

[0043] The following examples further illustrate the present invention, but do not constitute a limitation thereof. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the invention. In the examples, the ratio of raw material components in each transition layer and cladding layer is a mass ratio.

[0044] Example 1: A microtextured cutting tool based on in-situ laser microcladding. The tool substrate material is high-speed steel. Ni60, WC, and WS2 powders with particle sizes of 200 nm, 300 nm, and 2 μm are ball-milled in different proportions for 2 hours to ensure thorough mixing. A Ni60 powder layer is deposited on the rake face of the tool using electrofluid deposition. Then, a square microtexture with a side length of 50 μm is selectively processed using laser microcladding technology. The laser-irradiated substrate is then ultrasonically cleaned in alcohol to remove any unclad powder. The aforementioned steps are repeated to sequentially deposit and clad a Ni60+WC (Ni60:WC = 9:1) transition layer, a Ni60+WC+WS2 (Ni60:WC:WS2 = 90:5:5) cladding layer, and a Ni60+WC+WS2 (Ni60:WC:WS2 = 85:5:10) cladding layer on the tool substrate. Its characteristic is that each prepared individual microtexture has a multi-layer coating structure. The specific preparation process steps are as follows:

[0045] (1) Grind and polish the high-speed steel tool substrate, then ultrasonically clean it in an alcohol solution for 20 minutes to remove oil stains.

[0046] (2) A Ni60 powder layer with a thickness of about 10 μm was uniformly deposited on the surface of the high-speed steel tool substrate by electro-jet deposition. The slurry flow rate was 9-12 μL, the voltage was 3.5-4.1 kV, the metal nozzle moving speed was 10 mm / s, and the nozzle height from the substrate surface was 5 mm.

[0047] (3) A square microtexture with a side length of 50μm was designed in the laser computer. The laser irradiated the microtexture according to the designed shape, so that the powder layer in the laser irradiation area melted and formed a metallurgical bond with the matrix material, thereby processing the microtexture in situ on the surface of the tool matrix. The number of laser processing times was 1, the laser power was 18W, the spot diameter was 20μm, the laser scanning speed was 15mm / s, and the laser frequency was 20kHz.

[0048] (4) In order to prevent the un-laser-irradiated powder layer from affecting subsequent processing, the substrate after laser micro-cladding is placed in alcohol for ultrasonic cleaning for 10 minutes to remove the un-clad powder layer.

[0049] (5) An Ni60+WC powder layer with a thickness of about 10 μm was deposited by electro-jet deposition. The slurry flow rate was 9-12 μL, the voltage was 3.5-4.1 kV, the metal nozzle moving speed was 10 mm / s, and the nozzle height from the substrate surface was 5 mm.

[0050] (6) Place the substrate after depositing the Ni60+WC powder layer in the initial position under the laser, and continue to irradiate the microtextured area with the laser to melt the Ni60+WC powder layer.

[0051] (7) Place the laser-coated substrate in alcohol and ultrasonically clean it for 10 minutes to remove the uncoated powder layer;

[0052] (8) A Ni60+WC+WS2(5%) powder layer with a thickness of about 10μm was deposited by electro-jet deposition. The slurry flow rate was 9-12μL, the voltage was 3.5-4.1kV, the metal nozzle moving speed was 10mm / s, and the nozzle height from the substrate surface was 5mm.

[0053] (9) Place the substrate after depositing the Ni60+WC+WS2(5%) powder layer in the initial position under the laser, and continue to irradiate the microtextured area with the laser to melt the Ni60+WC+WS2(5%) powder layer.

[0054] (10) Place the laser-coated substrate in alcohol and ultrasonically clean it for 10 minutes to remove the uncoated powder layer;

[0055] (11) An Ni60+WC+WS2(10%) powder layer was deposited by electro-jet deposition with a thickness of about 10 μm, a slurry flow rate of 9-12 μL, a voltage of 3.5-4.1 kV, a metal nozzle moving speed of 10 mm / s, and a nozzle height of 5 mm from the substrate surface.

[0056] (12) The substrate after depositing the Ni60+WC+WS2(10%) powder layer is placed in the initial position under the laser, and the laser continues to irradiate the microtextured area to melt the Ni60+WC+WS2(10%) powder layer.

[0057] (13) Place the laser-coated substrate in alcohol and ultrasonically clean it for 10 minutes to remove the uncoated powder layer;

[0058] (14) Post-processing: Use silk polishing cloth to polish the laser micro-cladding tool to achieve the required surface roughness.

[0059] (15) After preliminary friction experiments, such as Figure 3 As shown, the results indicate that the friction coefficient of the novel microtextured tool is significantly reduced, with an average friction coefficient of 0.38, which is 45.7% lower than that of commonly used carbide tools.

[0060] Example 2: Microtextured cutting tool based on in-situ laser microcladding. The tool substrate material is cemented carbide. Ni60, WC, and WS2 powders with particle sizes of 200 nm, 300 nm, and 2 μm are ball-milled in different proportions for 2 hours to ensure thorough mixing. A Ni60 powder layer is deposited on the rake face of the tool using electrojournaling. Then, a crescent-shaped biomimetic pitcher plant microtexture with an inner diameter of 200 μm, an outer diameter of 150 μm, and a center-to-center distance of 100 μm is selectively processed using laser microcladding technology. The laser-irradiated substrate is then immersed in alcohol for ultrasonic cleaning of any unclad powder. Repeat the aforementioned steps to sequentially deposit and clad a Ni60+WC (Ni60:WC = 9:1) transition layer, a Ni60+WC+WS2 (Ni60:WC:WS2 = 90:5:5) cladding layer, and a Ni60+WC+WS2 (Ni60:WC:WS2 = 85:5:10) cladding layer on the tool substrate. The key feature is that each individual microtexture prepared has a multi-layer coating structure. The specific fabrication process steps are as follows:

[0061] (1) Grind and polish the carbide tool substrate, then ultrasonically clean it in an alcohol solution for 20 minutes to remove oil stains.

[0062] (2) A Ni60 powder layer with a thickness of about 10 μm was uniformly deposited on the surface of the high-speed steel tool substrate by electro-jet deposition. The slurry flow rate was 9-12 μL, the voltage was 3.5-4.1 kV, the metal nozzle moving speed was 10 mm / s, and the nozzle height from the substrate surface was 5 mm.

[0063] (3) A crescent-shaped biomimetic pitcher plant microtexture with an inner diameter of 200μm, an outer diameter of 150μm, and a center-to-center distance of 100μm was designed in the laser computer. The laser irradiates the microtexture according to the designed shape, so that the powder layer in the laser irradiation area melts and forms a metallurgical bond with the substrate material, thereby processing the microtexture in situ on the surface of the tool substrate. The number of laser processing times is 1, the laser power is 18W, the spot diameter is 20μm, the laser scanning speed is 15mm / s, and the laser frequency is 20kHz.

[0064] (4) In order to prevent the un-laser-irradiated powder layer from affecting subsequent processing, the substrate after laser micro-cladding is placed in alcohol for ultrasonic cleaning for 10 minutes to remove the un-clad powder layer.

[0065] (5) An Ni60+WC powder layer with a thickness of about 10 μm was deposited by electro-jet deposition. The slurry flow rate was 9-12 μL, the voltage was 3.5-4.1 kV, the metal nozzle moving speed was 10 mm / s, and the nozzle height from the substrate surface was 5 mm.

[0066] (6) Place the substrate after depositing the Ni60+WC powder layer in the initial position under the laser, and continue to irradiate the microtextured area with the laser to melt the Ni60+WC powder layer.

[0067] (7) Place the laser-coated substrate in alcohol and ultrasonically clean it for 10 minutes to remove the uncoated powder layer;

[0068] (8) A Ni60+WC+WS2(5%) powder layer with a thickness of about 10μm was deposited by electro-jet deposition. The slurry flow rate was 9-12μL, the voltage was 3.5-4.1kV, the metal nozzle moving speed was 10mm / s, and the nozzle height from the substrate surface was 5mm.

[0069] (9) Place the substrate after depositing the Ni60+WC+WS2(5%) powder layer in the initial position under the laser, and continue to irradiate the microtextured area with the laser to melt the Ni60+WC+WS2(5%) powder layer.

[0070] (10) Place the laser-coated substrate in alcohol and ultrasonically clean it for 10 minutes to remove the uncoated powder layer;

[0071] (11) An Ni60+WC+WS2(10%) powder layer was deposited by electro-jet deposition with a thickness of about 10 μm, a slurry flow rate of 9-12 μL, a voltage of 3.5-4.1 kV, a metal nozzle moving speed of 10 mm / s, and a nozzle height of 5 mm from the substrate surface.

[0072] (12) The substrate after depositing the Ni60+WC+WS2(10%) powder layer is placed in the initial position under the laser, and the laser continues to irradiate the microtextured area to melt the Ni60+WC+WS2(10%) powder layer.

[0073] (13) Place the laser-coated substrate in alcohol and ultrasonically clean it for 10 minutes to remove the uncoated powder layer;

[0074] (14) Post-processing: Use silk polishing cloth to polish the laser micro-cladding tool to achieve the required surface roughness.

[0075] (15) The prepared microtextured tool was subjected to friction experiments at different working conditions and speeds, such as Figure 4 As shown, the results indicate that the friction coefficient of the novel microtextured tool does not fluctuate significantly and can be applied to different working conditions.

[0076] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A microtextured tool based on in-situ laser microcladding forming, characterized in that, The microtextured tool includes at least a tool substrate. A Ni60 powder layer is deposited on the surface of the tool substrate. Then, a microtextured shape is fabricated in situ on the surface of the tool substrate with the deposited Ni60 powder layer using a laser microcladding method. Then, a Ni60+WC powder layer, a Ni60+WC+WS2 powder layer with a 5% mass fraction of WS2, and a Ni60+WC+WS2 powder layer with a 10% mass fraction of WS2 are sequentially deposited and clad using a laser microcladding method.

2. The microtextured tool as described in claim 1, characterized in that, The tool substrate is made of high-speed steel or cemented carbide.

3. The microtextured tool as described in claim 1, characterized in that, Each powder layer has a thickness of 20-50 μm.

4. The microtextured tool as described in claim 1, characterized in that, Remove uncoated powder after each use of laser micro-cladding.

5. The microtextured tool as described in claim 4, characterized in that, The cleaning was performed using ultrasonic cleaning with ethanol.

6. The method for preparing the microtextured tool based on laser microcladding in-situ forming as described in any one of claims 1-5, the method comprising: S1. Ni60 powder is uniformly deposited on the pretreated tool substrate surface using electro-jet deposition to obtain a Ni60 transition layer. S2. A micro-texture is fabricated in situ on the surface of a tool substrate with a Ni60 transition layer by using a laser micro-cladding method. The powder layer area after laser irradiation will be metallurgically bonded to the substrate, and then the unclad powder will be removed. S3. Repeat steps S1-S2 to sequentially deposit and clad Ni60+WC transition layer, Ni60+WC+WS2 cladding layer with 5% WS2 mass fraction and Ni60+WC+WS2 cladding layer with 10% WS2 mass fraction are obtained.

7. The preparation method according to claim 6, characterized in that, In step S1, the pretreatment method includes: grinding and polishing the tool substrate, and ultrasonically cleaning it in an alcohol solution for 10-30 minutes to remove oil stains; The tool substrate is made of high-speed steel or cemented carbide.

8. The preparation method according to claim 6, characterized in that, In steps S2 and S3, the specific parameters for laser micro-cladding are as follows: 1-2 processing times, scanning speed of 10-15 mm / s, laser power of 15-20 W, spot diameter of 15-30 μm, and laser frequency of 10-30 kHz.

9. The preparation method according to claim 6, characterized in that, The mass ratio of Ni60 to WC in the Ni60+WC transition layer is 9:

1. In a Ni60+WC+WS2 cladding layer with a WS2 mass fraction of 5%, the mass ratio of Ni60, WC, and WS2 is 90:5:

5. In a Ni60+WC+WS2 cladding layer with a WS2 mass fraction of 10%, the mass ratio of Ni60, WC, and WS2 is 85:5:

10. The average particle sizes of Ni60, WC, and WS2 are 200 nm, 300 nm, and 2 μm, respectively.

10. The preparation method according to claim 6, characterized in that, The preparation method further includes polishing the tool obtained in step S3 to achieve the desired surface roughness.

11. The application of the microtextured cutting tool according to any one of claims 1-5 in the cutting of difficult-to-machine metal materials.

12. The application as described in claim 11, characterized in that, The difficult-to-machine metal materials include stainless steel, titanium alloys, aluminum alloys, and nickel-based alloys.

Images