Papers by Author: Wei Zhang

Abstract: The experiment of laser cladding on the surface of Cr12 mold steel was made. Ni-coated nano-Al₂O₃ particles powder was used as cladding material. The microstructure and hardness of laser cladding layer were tested. The research showed that the compact cladding layer without crack, gas hole and other defects could be made by laser cladding. The cladding layer was made up of three phases, Fe-Ni solid solution, Fe-Cr solid solution and nano-Al₂O₃ particle. nano-Al₂O₃ particles enhanced the inhomogeneous nucleation of Fe-based alloy, refined the crystal grains and strengthened the mechanical properties of cladding layer. The average hardness of cladding zone was 900 HV0.2 which was 2.2 times higher than that of substrate.

Abstract: The experiment of laser cladding on the surface of 20 steel was made. The mixed powder of cobalt-based alloy powder (Co55) and tungsten powder was used as cladding material. There were three kinds of weight percent of tungsten powder, 5%, 10% and 15%. The microstructure and hardness of three kinds of laser cladding layer were studied. The microstructure of cladding zone was greatly refined after adding tungsten powder to Co55 powder. When the proportion of tungsten powder was 5%, the cladding zone was made up of dendritic crystal. The average hardness of cladding zone was 590 HV0.2. When the proportion of tungsten powder rose to 10%, there was reticular secondary carbide precipitating along the grain boundary. The average hardness of cladding zone was 648 HV0.2. When the proportion of tungsten powder rose to 15%, much granular carbide would diffusely distribute in Ni-based solid solution. The average hardness of cladding zone was 831 HV0.2.

Abstract: The experiments of laser cladding on the surface of 20 steel were made. High-chromium (Cr) cast iron powder was used as cladding material. The microstructure and hardness of laser cladding layers under different scanning speed were studied. The experiments showed that high-Cr cast iron cladding layer had better properties such as minute crystals, high density, no crack, no gas cavity and good metallurgical bonding with base metal. When the scanning speed was low, such as 10mm/min, the microstructure of cladding layer was cellular dendrite. There were much carbide with the shape of fish-bone distributing among cellular grains. Under higher scanning speed (from 100mm/min to 300mm/min), needle-shaped primary cementite would come into being. When laser scanning speed was 500mm/min, the carbide of cladding zone was very thin. With the increasing of laser scanning speed, the average hardness of cladding zone increased from 388HV0.2 to 580 HV0.2.

Abstract: The experiments of laser cladding on the surface of H13 steel were made. Molybdenum (Mo) wire and high-chromium (Cr) cast iron powder were used as cladding material. The microstructure and hardness of laser cladding layer were studied. The experiments showed that Mo wire and high-Cr cast iron cladding layer had better properties such as minute crystals, high density, no crack, no gas cavity and good metallurgical bonding with base metal. There was a slight melting on the surface of Mo wire which would greatly increase the binding force between Mo wire and high-Cr cast iron. Mo wire could make grain refine and limit the growing of carbide. The average hardness of junction zone of Mo wire and high-Cr cast iron was 750HV0.2 which was higher than that of cladding zone composed of high-Cr cast iron (650HV0.2).

Abstract: The process technology of critical component (named arm part) was adopted through the analysis of structure features. The suitable fixture was designed correspond to their process. The critical points of the fixture were explained. Practice has proved that process technology and fixture design have improved quality and machining precision, and the time cost on machining was decreased by 40%, which has enhanced the competitiveness of enterprise.

Abstract: The simulation of temperature field during laser direct metal deposition(DMD) were researched. The finite element model of single track cladding, multi-track overlapping and multi-layer deposition were established. The temperature field was simulated by ANSYS software basing on life-and-death element and cycle algorithm. Under different process parameters, the temperature and temperature gradient on the cross-section of sample were simulated during single- track scanning, multi-track overlapping and multi-layer deposition. Temperature cycle curves at different position were analyzed and were consistent with actually value. Both simulation and experiment showed that heat accumulation during continuous forming greatly affected the temperature of molten pool.

Abstract: Coaxial powder feeding with carrier gas is the key part of laser direct metal deposition (DMD) rapid prototyping system. The convergence of powder flow would greatly affect forming efficiency, precision and performance. Numerical calculation model of flow field was built and simulated in this paper. The results of simulation and analysis had shown that powder flow field was very complex. The flow process could be divided into two parts, converging process and dispersing process. The main influencing factors of convergence included powder feeding rate, carrier gas flow rate, and the distance from nozzle to molten pool. There was a convergent focus where utilization ratio of powder was maximum. So the distance from nozzle to molten pool must be adjusted to equal to convergent focus (1.5cm) during DMD.

Abstract: The experiment of laser alloying on the surface of P20 steel was made. Tungsten carbide (WC) powder was used as alloying material. The microstructure and property of laser alloying layer and nitriding layer are studied. The research showed that laser alloying layer had better properties such as minute crystals, deeper layer, higher hardness and good metallurgical bonding with base metal. The average hardness of alloying zone was 600HV0.2. The average hardness of phase-change hard zone was 450HV0.2. P20 steel was widely used in the field of plastic mold manufacture, especially mold core and cavity. Abrasion, corrosion and pressure resulted in change of mold size and shape which could greatly affect molding precision. Using laser alloying, the good wear layer would be made on the surface of p20 steel and would greatly increase the mold useful life.

Abstract: This paper was focus on the technical parameters matching model of laser direct metal deposition（DMD）forming. Based on a series of DMD forming experiments, the energy balance equation of laser power, beam radius, powder feeding velocity and scanning velocity was established which could provide a theoretical principle for parameter selection and optimizing.