Iron-Based Cladding Powder for High-Rate, Low-Heat Laser Deposition
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Solution Overview
Problem
Conventional laser cladding technology faces limitations due to low energy utilization, slow cladding rate, and large heat-affected zones, restricting its application, especially in achieving high wear resistance, corrosion resistance, and metallurgical bonding with substrates.
Innovation Solution
The development of an iron-based metal powder with specific chemical composition and processing parameters for ultra-high-speed laser cladding, including controlled particle size, fluidity, and sphericity, combined with high-energy-density laser processing, to form a dense, crack-free, and corrosion-resistant cladding layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser cladding technology is used, then the cladding layer can be formed with metallurgical bonding, but the cladding rate is slow and the heat-affected zone is large
Solution Approach 1:
The patent changes the physical state parameter of the metal powder from solid to liquid by pre-heating it to near its melting point before cladding. This parameter change enables the powder to absorb laser energy more efficiently and melt faster, thereby increasing the cladding rate while reducing the heat-affected zone on the substrate
2Use of energy by moving object
If conventional laser cladding technology is used, then the cladding layer can be formed, but the energy utilization is low and heat loss is large
Solution Approach 1:
The patent applies preliminary action by pre-heating the metal powder to near its melting point before the laser cladding process. This preliminary thermal treatment reduces the energy required during the actual cladding operation, thereby improving energy utilization and reducing heat loss to the surrounding environment and substrate
3Reliability
If Cr element is added to improve corrosion resistance, then corrosion resistance is enhanced, but the γ phase region shrinks making it difficult to obtain stable austenite
Solution Approach 1:
The patent uses composite material principle by combining Cr with Ni and Mn in specific proportions. Cr provides corrosion resistance, while Ni and Mn stabilize the austenite structure. This composite alloy composition achieves both corrosion resistance and stable austenite phase structure simultaneously
4Strength
If Ti and C are added to generate TiC hard phases for strengthening, then wear resistance is improved, but the reaction requires additional energy input
Solution Approach 1:
The patent applies preliminary action by pre-heating the metal powder before cladding, which provides the necessary thermal energy for the Ti and C elements to react and form TiC hard phases during the cladding process. This preliminary heating ensures adequate energy input for hard phase formation without requiring additional energy during cladding
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly enhances the cladding rate, improves wear resistance, corrosion resistance, and oxidation resistance, while reducing dilution rates and achieving a smooth, defect-free surface with improved metallurgical bonding.
Implementation Method 1
a high-power density laser beam is used to fuse the very thin layer on the surface of the substrate
Implementation Method 2
uses a high-energy-density beam to melt the additive material and the surface of substrate material
Implementation Method 3
quickly solidify to form a surface cladding layer with dense structure
Implementation Method 4
The in-situ synthesis of Ti and carbon is an exothermic reaction
Implementation Method 5
in-situ TiC and TiB2 hard phases are generated for strengthening
Data Source
AI summary
An iron-based metal powder for ultra-high-speed laser cladding comprising chemical composition and mass percentage of the metal powder of: C 0.6˜1.0%, Cr 17.0˜20.0%, Ni 5.0˜6.5%, Mn 2.0˜4.0%, Mo 1.0˜1.5%, Ti 4.0˜6.0%, B 1.0˜1.5%, N 0.08˜0.15%, Si≤0.5%, P≤0.030%, S≤0.030%, balance of Fe and unavoidable impurities, wherein the particle size of the metal powder is 15˜65 μm, the fluidity is 16˜20 s/50 g.