Search Results (47)

In this study, NiCrBSi composite coatings reinforced with 5–15 wt.% TiC particles were prepared using laser cladding to investigate the influence of the TiC content and laser beam power on the coatings’ quality, structure, and properties. Penetrant tests revealed the presence of cracks in the composite coatings, which were reduced with the higher laser power due to a decrease in cooling rate. A macroscopic analysis showed that pure NiCrBSi coatings exhibited a high quality and were free of defects, while the addition of TiC particles led to the formation of large pores, particularly in coatings produced with a lower laser power. Microstructural characterization was conducted using Scanning Electron Microscopy (SEM), Energy-Dispersive Spectroscopy (EDS), and X-ray Diffraction (XRD). The microstructure of the pure NiCrBSi coatings consisted of an austenitic matrix with chromium-based precipitates (carbides and borides). Variations in structural morphology across different regions of the coatings and under varying laser powers were described. When TiC particles were added, partial dissolution occurred in the molten pool, enriching it with titanium and carbon, which subsequently led to the precipitation of titanium carbides. The average microhardness of the composite coatings increased by 28%–40% compared to the pure NiCrBSi coating, while the erosion resistance remained comparable. Solid particle erosion tests in accordance with the ASTM G76-18 standard resulted in average erosion values of the pure NiCrBSi coating of 0.0056 and 0.0025 mm³/g for the 30° and 90° impingement angles, respectively. Full article

Laser cladding technology is an effective method for producing wear-resistant coatings on damaged substrates, improving both wear and corrosion resistance, which extends the service life of components. However, the fabrication of hard and brittle materials is highly susceptible to the problem of cracking. Using gradient transition layers is an effective strategy to mitigate the challenge of achieving crack-free laser-melted wear-resistant coatings. This study presents the cracking issue of laser cladding Ni60B (NiCrBSi) coatings on 38CrMoAl (18CrNiMo7-6) steel by designing a gradient transition layer infused with varying amounts of Ni powder. We examine how different levels of Ni doping in the transition layer influence the fabrication of the Ni60B coating. The results indicate that the cracking mechanism of Ni60B is primarily due to the brittleness and hardness of the fusion cladding layer, which can result in cold cracks under residual tensile stress. Increasing the nickel content in the transition layer reduces the difference in thermal expansion coefficients between the cladding layer and the substrate. Additionally, the nickel in the transition layer permeates the cladding layer due to the laser remelting effect. The physical phase within the cladding layer transitions from the initial CrB, M₇C₃, and γ-Ni solid solution to γ-Ni solid solution and Ni-B-Si eutectic, with a small amount of boride and carbide hard phases. As the nickel doping in the transition layer increases, the proportion of the toughness phase dominated by Ni elements significantly rises, leading to a decrease in the hardness of the fused cladding layer. However, the average hardness of the fusion cladding layer in crack-free samples was measured at 397.5 ± 5.7 HV_0.2, which is 91% higher than that of the substrate. Full article

To improve the wear resistance of the Ti60 alloy, laser cladding was used to obtain a composite coating containing a high-entropy (Ti_0.2Zr_0.2Mo_0.2Ta_0.2Nb_0.2)B₂ boride phase, with Ti, Zr, Mo, Ta, Nb, and B powders as the raw materials. The microstructure and wear characteristics of the coating were studied using XRD, SEM, EDS, and the pin-on-disc friction wear technique. The results show that the coating mainly consists of six phases: (Ti_0.2Zr_0.2Mo_0.2Ta_0.2Nb_0.2)B₂, ZrB₂, TiB, TiZr, Ti_1.83 Zr_0.17, and Ti_0.67Zr_0.67Nb_0.67. The average microhardness of the coating was 1062.9 HV_0.1 due to the occurrence of the high-entropy, high-hardness (Ti_0.2Zr_0.2Mo_0.2Ta_0.2Nb_0.2)B₂ boride phase, which was about 2.9 times that of the Ti60 alloy substrate. The coating significantly improved the wear resistance of the Ti60 alloy substrate, and the mass wear rate was about 1/11 that of the Ti60 alloy substrate. The main types of wear affecting the coating were abrasive, adhesive, and oxidation wear, while the main wear affecting the Ti60 alloy matrix was abrasive wear, accompanied by a small amount of adhesive and oxidation wear. Full article

The surface of 17-4PH martensitic stainless steel was laser-cladded with Ni60 and Ni60+nano-WC composites and a comprehensive investigation was conducted of the microstructure and wear mechanism. The findings demonstrate that despite the added nano-WC particles being fused and dissolved during laser cladding, they still lead to a reduction in grain size and a decrease in crystallographic orientation strength. Furthermore, the dissolution of nano-WC makes the lamellar M₂₃C₆ carbides transform into a rod or block morphology, and leads to the CrB borides becoming finer and more evenly dispersed. This microstructural evolution resulted in a uniform increase in hardness and wear resistance, effectively preventing crack formation. When the nano-WC addition increased to 20 wt.%, there was a 27.12% increase in microhardness and an 85.19% decrease in volume wear rate compared to that of the pure Ni60 coating. Through analysis of the microstructure and topography of wear traces, it can be inferred that as the nano-WC addition increased from 0 wt.% up to 20 wt.%, there was a gradual transition from two-body abrasive wear to three-body abrasive wear, ultimately resulting in adherent wear. Full article

In order to improve the high-temperature oxidation resistance of Ti60 alloy, a Ti-Hf-Mo-Ta-Nb-B composite coating was prepared on Ti60 alloy with Ti, Hf, Mo, Ta and Nb powder and B powder as raw materials using laser cladding. The microstructure and oxidation behavior of the coating before and after oxidation at 1100 °C × 120 h in static air were studied with XRD, SEM, EDS and isothermal oxidation techniques. The results show that the coating was mainly composed of six phases, (Ti_0.2Hf_0.2Mo_0.2Ta_0.2 Nb_0.2)B₂, TiB, HfB₂, Mo_4.00 B_3.40, TiHf and Hf_1.86Mo_0.14. The high-temperature oxidation of the coating and Ti60 alloy followed parabolic law, and the oxidation weight gain rate of the coating after 110 °C × 120 h was only 1/4.8 of that of the Ti60 alloy. The improvement of the high-temperature oxidation resistance of the coating may benefit from high-temperature oxidation resistance (Ti_0.2Hf_0.2 Mo_0.2Ta_0.2Nb_0.2)B₂, HfB₂ and TiB boride ceramic phases. Full article

The features of oxidation of ultra-high-temperature ceramic material HfB₂-30 vol.%SiC modified with 1 vol.% graphene as a result of supersonic flow of dissociated CO₂ (generated with the use of high-frequency induction plasmatron), as well as under the influence of combined heating by high-speed CO₂ jets and ytterbium laser radiation, were studied for the first time. It was found that the addition of laser radiation leads to local heating of the central region from ~1750 to ~2000–2200 °C; the observed temperature difference between the central region and the periphery of ~300–550 °C did not lead to cracking and destruction of the sample. Oxidized surfaces and cross sections of HfB₂-SiC-C_G ceramics with and without laser heating were investigated using X-ray phase analysis, Raman spectroscopy and scanning electron microscopy with local elemental analysis. During oxidation by supersonic flow of dissociated CO₂, a multilayer near-surface region similar to that formed under the influence of high-speed dissociated air flows was formed. An increase in surface temperature with the addition of laser heating from 1750–1790 to 2000–2200 °C (short term, within 2 min) led to a two to threefold increase in the thickness of the degraded near-surface area of ceramics from 165 to 380 microns. The experimental results indicate promising applications of ceramic materials based on HfB₂-SiC as part of high-speed flying vehicles in planetary atmospheres predominantly composed of CO₂ (e.g., Venus and Mars). Full article

An important direction in the development of additive technologies is associated with the addition of ceramic particles (oxide, carbide, boride, and nitride ceramics) to metal powders. The prediction of the physical and mechanical characteristics of SiC-particle-reinforced composite materials (PRCMs) in comparison with experimental results was studied. A near-α Ti-4.25Al-2V titanium-alloy-based composite reinforced by 1 vol.% of SiC ceramic particles was produced using laser direct energy deposition. A multiscale modeling approach at the micro and macro levels was applied. At the micro level, the toughness and strength characteristics for a temperature interval of T = 20–450 °C were predicted using a representative volume element of PRCM with the nearly real shape of SiC particles. At the macro level, the features of plastic deformation and fracture of the PRCM were predicted by numerical modeling using the commercial software Digimat Student Edition ver. 2022.4 and Ansys Student 2023 R2. The addition of SiC particles was found to improve the physical and mechanical properties in the whole temperature range. The results of the numerical modeling were consistent with the experimental data (the deviation did not exceed 10%). The proposed approach for predicting the physical and mechanical properties of Ti-4.25Al-2V/SiC can also be used for other PRCMs obtained by laser direct energy deposition. Full article

The development of new efficient, economical, and safe methods for strengthening the working surfaces of parts is an important task in the field of improving the reliability and resourcefulness of critical equipment and structures. In the present paper, laser boronizing is investigated as an alternative method for improving the wear resistance of maraging steel parts manufactured by laser powder bed fusion (LPBF). After LPBF, the specimens’ surface was covered with an amorphous boron paste (0.03–0.6 mm) and laser processed with a continuous-wave fiber laser in melting mode (λ—1070 nm; power—300 W; spot Ø—1.0 mm) at 500–1500 mm/min laser beam scanning speeds. Scanning electron microscopy, X-ray microanalysis, Knoop hardness, and dry sliding wear tests were applied to investigate the geometry, microstructure, hardness and its distribution, heat-affected zones, wear resistance, and wear mechanism of the alloyed layers. The boronized layers of thickness ~280–520 µm with microstructure from hypoeutectic to borides’ mixture were obtained, whose hardness varied from ~490 to ~2200 HK0.2. With laser boronizing, the wear resistance was improved up to ~7.5 times as compared with aged LPBF samples. In further method development, the problem of thermal cracking and softening of the heat-affected zone should be solved. Full article

Nickel-based Ni-Cr-Si-B self-fluxing alloys are excellent candidates to replace cobalt-based alloys in aeronautical components. In this work, metal additive manufacturing by directed energy deposition using a laser beam (DED-LB, also known as LMD) and gas-atomized powders as a material feedstock is presented as a potential manufacturing route for the complex processing of these alloys. This research deals with the advanced material characterization of these alloys obtained by LMD and the study and understanding of their solidification paths and strengthening mechanisms. The as-built microstructure, the Vickers hardness at room temperature and at high temperatures, the nanoindentation hardness and elastic modulus of the main phases and precipitates, and the strengthening mechanisms were studied in bulk cylinders manufactured under different chemical composition grades and DED-LB/p process parameter sets (slow, normal, and fast deposition speeds), with the aim of determining the influence of the chemical composition in commercial Ni-Cr-Si-Fe-B alloys. The hardening of Ni-Cr-Si-Fe-B alloys obtained by LMD is a combination of the solid solution hardening of gamma nickel dendrites and eutectics and the contribution of the precipitation hardening of small chromium-rich carbides and hard borides evenly distributed in the as-built microstructure. Full article

Tantalum boride is an ultra-refractory and ultra-hard ceramic known so far for its favorable high-temperature thermo-mechanical properties and also characterized by a low spectral emittance, making it interesting for novel high-temperature solar absorbers for Concentrating Solar Power. In this work, we investigated two types of TaB₂ sintered products with different porosities, and on each of them, we realized four femtosecond laser treatments differing in the accumulated laser fluence. The treated surfaces were then characterized by SEM-EDS, roughness analysis, and optical spectrometry. We show that, depending on laser processing parameters, the multi-scale surface textures produced by femtosecond laser machining can greatly increase the solar absorptance, while the spectral emittance increase is significantly lower. These combined effects result in increased photothermal efficiency of the absorber, with interesting perspectives for the application of these ceramics in Concentrating Solar Power and Concentrating Solar Thermal. To the best of our knowledge, this is the first demonstration of successful photothermal efficiency enhancement of ultra-hard ceramics using laser machining. Full article

Laser boriding is a surface treatment that involves the simultaneous re-melting and mixing of the alloying material, containing amorphous boron blended with diluted polyvinyl alcohol, with the substrate material (Nimonic 80A-alloy). As a result of high cooling rates, the boride layer is formed from a solidifying molten pool. The thickness of the produced layer depends on the laser treatment parameters, e.g., power of the laser beam, scanning rate, and laser beam radius. These parameters influence the temperature distribution on the cross-section of laser tracks and, thus, directly determine the size of the molten pool, from which the boride layer is formed after crystallization. In the present study, laser borided layers were produced on Nimonic 80A alloy using a CO₂ molecular laser. Differences in the laser beam power used resulted in the formation of layers of different thicknesses, which resulted directly from the differences in the temperature distribution in the treated material. The amount of boron in the molten pool directly influenced the obtained hardness of the laser borided layer. It was found that the lower laser beam power had an advantageous effect on the hardness due to the higher percentage of nickel borides and chromium borides in the layer. The reasons for this situation are discussed in detail. Full article

A mixture of original 1CP powder and 10 wt.% of pure Cu-powder was prepared and 1CP-Cu composite samples were obtained by selective laser melting using different process parameters. Comparison of pure 1CP and composite samples showed that addition of Cu halved the porosity percentage of the obtained material. Distribution of Cu-phase in 1CP-matrix can be recognized as uniform in all the samples. X-ray diffraction of samples showed the presence of α-Fe solid solution, iron boride Fe₂B, and crystal Cu. Scanning electron microscopy analysis also allowed to discover ordered solid solution Fe₃Si in samples microstructure. Differential scanning calorimetry data showed that composite sample contains amorphous phase as opposed to pure 1CP sample manufactured using the same process parameters. Magnetic properties of samples were studied, and it was found that addition of 10 wt.% of Cu allowed to reduce magnetic field energy losses by approximately four times. Full article

Grain refinement through borides is known to be suppressed when TiAl is welded with a laser beam. As β grains do not primarily nucleate on boride at a high cooling rate, a mixture of nitrogen and argon is applied as a protecting gas for the formation of TiN during solidification. The phase transformation is changed correspondingly from Liquid → Liquid + β → β → α + β → α + γ+ β → α₂ + γ + B2 to Liquid → TiN + Liquid → β+ TiN → α + γ + TiN → α₂ + γ+ TiN. It is found that β grains prefer to nucleate heterogeneously on the suspending TiN in the melt with orientation relationship ${\text{{}111\text{}}}_{\mathrm{TiN}}//{\left\{110\right\}}_{\mathsf{\beta }}$, leading to refined β grains. α₂ colonies that were thus modified into fine non-dendritic grains. The effects of nitrogen as a shielding atmosphere on the microstructure evolution of TiAl are elaborately studied. Full article

The multicomponent alloys with nearly equal concentration of components, also known as high entropy alloys (HEAs), were first proposed 22 years ago. The HEAs quickly became very important in materials science due to their unique properties. Nowadays, the HEAs are frequently used in energy conversion and storage applications. HEAs can consist of five, six or more components. Plasma cladding permits coating of the large surfaces of cheap substrates with (often expensive) HEAs and to enlarge, in such a way, their application area. The large-area coatings deposited by plasma cladding possess multiple advantages such as low thermal distortion, very high energy density, as well as low dilution of the substrate material. Plasma cladding ensures good metallurgical bonding between coating and substrate. The costs of operation and equipment are also very attractive. During plasma cladding, the mixed powders are blown by carrier gas into a plasma torch or are positioned on a substrate. This powder mixture is then melted in or under the plasma torch. The plasma torch, in turn, sequentially scans the substrate. After finalizing the crystallization process, the solid polycrystal appears which contains few residual melts. This remaining melt can completely or incompletely wet the grain boundaries (GBs) in solid phase of the polycrystal. These completely or incompletely wetted GBs can strongly influence the microstructure of HEA coatings and their morphology. In this review we analyze the GB wetting HEAs containing one phase in HEAs with two, three and more phases, as well as in HEAs reinforced with particles of carbides, nitrides, borides, or oxides. We also analyze the microstructure of the rather thick coatings after plasma cladding after additional laser remelting and observe how GB wetting changes over their thickness. Full article

The process parameters of laser cladding have a significant influence on the forming quality of the coating. This research investigates the relationship between input process parameters (laser power, scanning speed, pre-placed thickness) and output responses (height, width, dilution rate) of Mo₂FeB₂ coating through sensitivity analysis. The microstructure and properties of selected coatings were analyzed to discuss the corresponding relations. The results showed that the laser power positively affected the coating width and dilution rate, while negatively affecting the coating height. The scanning speed had a negligible effect on the height and dilution rate. The pre-placed thickness had a positive influence on the height and width; it negatively affected the dilution rate. Based on the sensitivity analysis, the thickness of the pre-placed coating determined the most sensitivity to the height. The sensitivity of the width to laser power was the highest among all parameters. The sensitivity of dilution rate to laser power and pre-placed powder thickness showed a noticeable impact. When the scanning speed was 3 mm/s, the forming quality of coating had a significant sensitivity for a higher or lower laser power (1.5, 2.1 kW) and higher or lower powder thickness (0.8, 1.2 mm). The analysis of microstructure and microhardness of Mo₂FeB₂ coating indicates that the Mo₂FeB₂ coating improves substrate properties. The microhardness of the Mo₂FeB₂ coating was 4–6 times that of the substrate, and the highest microhardness could be obtained by 1.5 kW laser power, 3 mm/s scanning speed, and 1.2 mm powder thickness from the sensitivity analysis results. Full article