High-flux component design method of nickel-based wear-resistant alloy for laser cladding

Abstract

The invention provides a novel high-flux component design method of a nickel-based wear-resistant alloy for laser cladding, and relates to the technical field of component design of nickel-based wear-resistant alloys and laser cladding, in particular to a component design method of a nickel-based wear-resistant alloy for laser cladding. The invention aims to develop a wear-resistant alloy material for laser cladding with excellent obdurability by taking Ni60 alloy as an example. In the specific implementation process, firstly, a Vickers hardness (HV) prediction model and a fracture toughness (KIC) prediction model of the nickel-based alloy are constructed; vickers hardness (HV) values and fracture toughness (KIC) values of tens of thousands of alloys are obtained through high-flux thermodynamics calculation, and Pareto alloy components are screened out according to the Vickers hardness (HV) values and the fracture toughness (KIC) values. The core value of the method is that a key component-performance associated data support and a systematic design methodology are provided for efficient research and development and large-scale production of the nickel-based wear-resistant alloy for laser cladding.

Description

Technical Field

[0001] This invention relates to laser cladding and nickel-based wear-resistant alloy composition design technology, and in particular provides a method for designing the composition of nickel-based wear-resistant alloys for laser cladding. Background Technology

[0002] In industries such as machinery manufacturing, mining and metallurgy, and aerospace, numerous critical components, such as crusher hammers, excavator bucket teeth, gear shafts, and turbine blades, are subjected to harsh service environments involving high-speed friction. The surfaces of these components directly bear the repeated frictional wear from external media. Existing traditional nickel-based coatings, due to a mismatch between wear resistance and toughness, cannot withstand rapid surface wear caused by high-intensity friction, often exhibiting problems such as "wear resistance meets standards but toughness is insufficient" or "toughness is acceptable but wear resistance is inadequate," leading to premature component failure and increased equipment maintenance costs. To address this issue, there is an urgent need to develop a nickel-based alloy coating that simultaneously achieves high hardness, high wear resistance, and reliable toughness to improve the surface protection and service life of components.

[0003] Ni60 alloy, as one of the most widely used nickel-based wear-resistant alloys in the field of laser cladding, plays an important role in the repair and strengthening of worn parts due to its excellent wear resistance, oxidation resistance, and process compatibility. Its core advantage stems from the synergistic effect of multiple alloying elements: chromium forms a dense chromium oxide protective film, improving the coating's oxidation and corrosion resistance; boron and silicon, as strong deoxidizers and slagging agents, improve the fluidity of the molten pool and refine the grains, while also forming hard intermetallic compounds with nickel and chromium, significantly improving the coating's hardness and wear resistance. However, traditional Ni60 alloy composition systems are mostly based on modified classic formulas, resulting in problems such as long composition design cycles and unclear correlations between element ratios and performance. Furthermore, while improving hardness and wear resistance, they often suffer from insufficient toughness, leading to coating cracking in practical applications. Facing different wear conditions, it is difficult to quickly achieve precise performance matching, limiting its further application in high-end equipment.

[0004] Addressing the core pain point of traditional Ni60 alloy composition design and performance matching, the key lies in establishing a precise "composition-performance" correlation model. Clarifying the intrinsic relationship between hardness and wear resistance, and using hardness as the core evaluation index for wear resistance, is a crucial foundation for building this model. From the perspective of the essence of friction and wear, wear is the process of plastic deformation, adhesion, cutting, or fatigue spalling of a material surface under external loads. Hardness, as the material's ability to resist localized plastic deformation, indentation, or scratching, directly determines its ability to resist these wear forms. A stable positive correlation exists between the two: higher hardness means a stronger ability to resist cutting, grooving, and adhesion by wear media, resulting in less wear and better wear resistance. The core significance of establishing an alloy composition design model lies in breaking the limitations of the traditional "trial and error" method, achieving precise derivation from composition control to performance prediction. This not only clarifies the influence mechanism of multiple alloying elements on coating hardness and wear resistance but also provides theoretical support for subsequent high-throughput calculations to quickly screen alloy compositions suitable for different working conditions, ensuring the efficiency and accuracy of composition design.

[0005] Based on this, this invention proposes a high-throughput laser cladding method for designing the composition of nickel-based wear-resistant alloys, aiming to construct a composition optimization system that balances efficiency and accuracy. This method utilizes high-throughput calculations of the thermodynamic parameters of tens of thousands of alloy components to establish a multi-element interaction model for Ni60 alloys, clarifying the influence mechanism of key elements on coating microstructure and wear resistance, ultimately achieving rapid design and optimization of alloy composition under target service conditions. The establishment of this method not only provides data support and technical reference for the industrial production of Ni60 alloys for laser cladding but also offers new ideas and methods for the high-throughput research and development of nickel-based wear-resistant alloys. Summary of the Invention

[0006] Purpose of the invention: To address the problems existing in the prior art, this invention proposes a high-throughput nickel-based wear-resistant alloy composition design method for laser cladding, which guides the efficient and accurate design of nickel-based wear-resistant alloy compositions with excellent strength and toughness.

[0007] Technical Solution: To achieve the above objectives, the present invention mainly provides the following technical solution:

[0008] On the one hand, a Vickers hardness model (HV) for a nickel-based wear-resistant alloy used in laser cladding is as follows:

[0009]

[0010] This model can predict the Vickers hardness of laser-clad nickel-based wear-resistant alloys relatively well, and the prediction effect is as follows: Figure 1 As shown.

[0011] One method for modeling the Vickers hardness (HV) model of a nickel-based wear-resistant alloy for laser cladding includes the following steps: P1: Establish a Vickers hardness prediction model based on the solid solution strength provided by each element to the matrix and the contributions of carbides, borides, and silicides to the alloy hardness; P2: Collect composition and Vickers hardness data of nickel-based wear-resistant alloys from the literature to form a composition-performance database; P3: Calculate the solidification process of each component alloy using the thermodynamic database to obtain the volume fraction of each phase; P4: Calculate and fit the Vickers hardness model using the P2 database.

[0012] On another front, a fracture toughness model (K) for a nickel-based wear-resistant alloy used in laser cladding is presented. IC The specific model is as follows:

[0013]

[0014] One of them is a fracture toughness model (K) of a nickel-based wear-resistant alloy for laser cladding. IC The modeling method for nickel-based wear-resistant alloys includes the following steps: S1: Establish a fracture toughness model based on the contribution of the tough phase and the hard phase to the fracture toughness; S2: Collect composition and fracture toughness data of nickel-based wear-resistant alloys from the literature to form a composition-performance database; S3: Calculate the solidification process of each alloy component through the thermodynamic database to obtain the volume fraction of each phase; S4: Calculate and fit the fracture toughness model using the S2 database.

[0015] A novel high-throughput composition design method for nickel-based wear-resistant alloys for laser cladding includes the following steps: N1: Pre-define N alloying elements other than nickel and their search ranges, where N is 6. The pre-defined alloying element (wt.%) search range is: Cr 7-18, B 1-5, C 0.2-1, Si 3-5, Fe 2-10, Ti 0-3.2, generating a series of candidate alloys with different compositions; N2: Obtain relevant thermodynamic information of the candidate alloys through high-throughput thermodynamic calculations; N3: Calculate the Vickers hardness and fracture toughness values ​​of the candidate alloys based on the volume fractions of each phase obtained in step N2; N4: Calculate the Vickers hardness and fracture toughness values ​​of the candidate alloys based on the results of step N3 and plot the Pareto front of the candidate alloy performance indicators, selecting the specific composition of the desired laser cladding nickel-based wear-resistant alloy. The alloy (wt.%) at one of the Pareto fronts is: Cr 18, B 4, C 0.4, Si 5, Fe 9, Ti 2.9, Ni Bal.

[0016] In summary, a novel high-throughput composition design method for nickel-based wear-resistant alloys used in laser cladding is presented. This method is simple in procedure and rationally designed, enabling the rapid establishment of a correlation database between alloy composition and mechanical properties. Based on actual production needs, a series of alloy compositions are screened to optimize the final design composition for the nickel-based wear-resistant alloy used in laser cladding. This effectively saves material development costs and accelerates the research and development process of new materials. This method can help achieve the excellent high strength and toughness of nickel-based wear-resistant alloys used in laser cladding.

[0017] The innovative aspects of this invention are as follows:

[0018] (1) Innovatively construct a “composition-performance” correlation model to break through the bottleneck of the fuzzy correlation between element ratio and performance in the traditional Ni60 alloy composition design. With the positive correlation between hardness and wear resistance as the core, establish a multi-element interaction model to realize the derivation from composition control to performance prediction.

[0019] (2) High-throughput computing enables efficient component screening. The innovative use of high-throughput computing technology allows for batch analysis of the thermodynamic parameters of tens of thousands of alloy components, replacing the traditional inefficient "trial and error" test mode, greatly improving the efficiency of alloy component screening and optimization, and significantly shortening the R&D cycle.

[0020] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0021] (1) The accuracy of composition design is significantly improved and the adaptability is stronger: This invention solves the problem of fuzzy correlation between composition and performance of traditional Ni60 alloy by constructing a "composition-performance" correlation model, and effectively solves the cracking problem of traditional Ni60 alloy.

[0022] (2) Improved R&D efficiency and reduced costs: This invention integrates high-throughput computing technology to analyze the thermodynamic parameters of alloy composition in batches, replacing the traditional inefficient "trial and error" test mode, which greatly improves the efficiency of alloy composition screening and optimization, significantly shortens the R&D cycle, and reduces the material and manpower cost losses caused by repeated tests. Attached Figure Description

[0023] Figure 1 The Vickers hardness (HV) model prediction effect of nickel-based wear-resistant alloys for laser cladding is shown in the figure.

[0024] Figure 2 Fracture toughness model of nickel-based wear-resistant alloys for laser cladding (K IC Predicted results diagram.

[0025] Figure 3 For Vickers hardness (HV) model and fracture toughness (K) IC Pareto front plot of the model.

[0026] Figure 4 Flowchart of a high-throughput composition design method for nickel-based wear-resistant alloys for laser cladding. Detailed Implementation

[0027] To clearly illustrate the inventive purpose, technical solutions, and beneficial effects of the embodiments of the present invention, the technical solutions in the embodiments of the present invention will be clearly and comprehensively explained below with reference to the accompanying drawings. Obviously, the embodiments detailed herein are only some representative embodiments of the present invention and not all implementations thereof. Based on the embodiments disclosed in this invention, all other embodiments derived by those skilled in the art without creative effort should be included within the protection scope of this invention.

[0028] [First Embodiment]

[0029] The first embodiment of the present invention provides a Vickers hardness model (HV) for a nickel-based wear-resistant alloy used in laser cladding, as detailed below:

[0030]

[0031] See Figure 1 The first embodiment of the present invention provides a modeling method for a Vickers hardness (HV) model of high-throughput composition design of nickel-based wear-resistant alloys for laser cladding, comprising the following steps:

[0032] Step P1: Establish a Vickers hardness model based on the solid solution strength provided by each element to the matrix and the contributions of carbides, borides and silicides to the alloy hardness.

[0033] Step P2: Collect composition and Vickers hardness data of nickel-based wear-resistant alloys from the literature to form a composition-performance database;

[0034] Step P3: Calculate the solidification process of each alloy component using a thermodynamic database to obtain the volume fraction of each phase;

[0035] Step P4: Calculate and fit the Vickers hardness model using the P2 database.

[0036] [Second Embodiment]

[0037] The second embodiment of the present invention provides a fracture toughness model of a nickel-based wear-resistant alloy for laser cladding ( ), as detailed below:

[0038]

[0039] See Figure 2 The second embodiment of the present invention provides a fracture toughness model (K) for high-throughput composition design of nickel-based wear-resistant alloys for laser cladding. IC The modeling method for ) includes the following steps:

[0040] Step S1: Establish a fracture toughness model based on the contributions of the ductile phase and the hard phase to the fracture toughness.

[0041] Step S2: Collect composition and fracture toughness data of nickel-based wear-resistant alloys from the literature to form a composition-performance database;

[0042] Step S3: Calculate the solidification process of each alloy component using a thermodynamic database to obtain the volume fraction of each phase;

[0043] Step S4: Calculate and fit the fracture toughness model using the S2 database.

[0044] [Third Embodiment]

[0045] The third embodiment of the present invention provides a new method for high-throughput composition design of nickel-based wear-resistant alloys for laser cladding, comprising the following steps:

[0046] Step N1: Predefine N alloying elements other than nickel and their search ranges, where N in step N1 is 6; the predefined search range for alloying elements (wt.%) is: Cr 7-18, B 1-5, C 0.2-1, Si 3-5, Fe 2-10, Ti 0-3.2. Approximately 97,000 alloy compositions are generated within the predefined and alloying element search ranges.

[0047] Step N2: Obtain relevant thermodynamic information of candidate alloys through high-throughput thermodynamic calculations;

[0048] Step N3: Based on the volume fraction of each phase in the candidate alloy obtained in Step N2, calculate the Vickers hardness and fracture toughness of the candidate alloy.

[0049] Step N4: Based on the results of step N3, calculate the Vickers hardness and fracture toughness values ​​of the candidate alloys and plot the Pareto front of the performance indicators of the candidate alloys. Select the specific composition of the desired laser cladding nickel-based wear-resistant alloy. One of the alloys (wt.%) in the Pareto front is: Cr 18, B 4, C 0.4, Si 5, Fe 9, Ti 2.9, Ni Bal.

Claims

1. A Vickers hardness model (HV) for a nickel-based wear-resistant alloy used in laser cladding, as detailed below:

2. A modeling method for the Vickers hardness (HV) model of nickel-based wear-resistant alloys for laser cladding, characterized in that, Includes the following steps: Step P1: A Vickers hardness prediction model is established based on the solid solution strength provided by each element to the matrix and the contributions of carbides, borides, and silicides to the alloy hardness, as detailed below: Where a, b, c, d, e, and k are undetermined coefficients, and σ ss f is the solid solution strength. γ It is the volume fraction of the γ phase, f MC It is the volume fraction of the MC phase, f MB It is the volume fraction of MB, f MSi It is the volume fraction of MSi, β i x is the solid solution strengthening coefficient of the i-th element. i It is the concentration of the i-th element. Step P2: Collect the composition and Vickers hardness data of nickel-based wear-resistant alloys from the literature to form a composition-performance database; Step P3: Calculate the solidification process of each alloy composition using the thermodynamic database to obtain the volume fraction of each phase; Step P4: Calculate and fit the Vickers hardness model using the P2 database.

3. A fracture toughness model (K) of a nickel-based wear-resistant alloy for laser cladding. IC ), as detailed below:

4. A fracture toughness model (K) of a nickel-based wear-resistant alloy for laser cladding. IC The modeling method of ) is characterized by, The steps include: Step S1: Establish a fracture toughness model based on the contributions of the ductile phase and the hard phase to the fracture toughness, as follows: Among them, E Ni f is the elastic modulus; γ It is the volume fraction of the γ phase; σ ss X is the solid solution strength; X is the fracture work of the ductile phase; a0 is the radius of the ductile phase; β i x is the solid solution strengthening coefficient of the i-th element. i It is the concentration of the i-th element. Step S2: Collect the composition and fracture toughness data of nickel-based wear-resistant alloys from the literature to form a composition-performance database; Step S3: Calculate the solidification process of each alloy composition using the thermodynamic database to obtain the volume fraction of each phase; Step S4: Calculate and fit the fracture toughness model using the S2 database.

5. A novel method for designing high-throughput composition of nickel-based wear-resistant alloys for laser cladding, characterized in that, Includes the following steps: Step N1: Preset N alloying elements other than nickel and their search range to generate a series of candidate alloys with different compositions; Step N2: Obtain relevant thermodynamic information of the candidate alloys through high-throughput thermodynamic calculations; Step N3: Calculate the Vickers hardness and fracture toughness values ​​of the candidate alloys based on the volume fraction of each phase obtained in Step N2; Step N4: Calculate the Vickers hardness and fracture toughness values ​​of the candidate alloys based on the results of Step N3, plot the Pareto front of the candidate alloy performance indicators, and select the specific composition of the desired laser cladding nickel-based wear-resistant alloy.

6. A novel method for high-throughput composition design of nickel-based wear-resistant alloys for laser cladding according to claim 5, characterized in that, This invention is based on the existing Ni60 alloy as an example, and performs composition optimization. In step N1, N is 6. The predefined alloy element (wt.%) search range is: Cr 7-18, B 1-5, C 0.2-1, Si 3-5, Fe 2-10, Ti 0-3.

2.

7. A novel method for high-throughput composition design of nickel-based wear-resistant alloys for laser cladding according to claim 5, characterized in that, Step N3 includes the following steps: Step N3.1: Based on the results in step N2, extract the volume fraction of each phase when solidification is complete; Step N3.2: Substitute the results in N3.1 into the Vickers hardness model and fracture toughness model in steps P4 and S4 to calculate the Vickers hardness value and fracture toughness value of the candidate alloy, and plot the Pareto front.

8. The high-throughput composition design method for nickel-based wear-resistant alloys for laser cladding according to claim 6, characterized in that, The alloy (wt.%) of one of the Pareto fronts in step N4 is: Cr 18, B 4, C 0.4, Si 5, Fe 9, Ti 2.9, Ni Bal.

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