Residual Stress Analysis and Shape Optimization of Laser Cladded Ni-Based Alloy Coatings

Table 1. Chemical compositions of 45 steel (mass fraction, %)
View table
Table 1. Chemical compositions of 45 steel (mass fraction, %)
Element C Si Mn P S Cr Ni Fe
Value 0.420-0.500 0.170-0.370 0.500-0.800 ≤0.035 ≤0.035 ≤0.250 ≤0.280 Bal.

Table 2. Chemical compositions of Ni60 powder (mass fraction, %)
View table
Table 2. Chemical compositions of Ni60 powder (mass fraction, %)
Element C Cr Si W Fe B Ni
Value 0.80 15.50 4.00 3.00 15.00 3.50 Bal.

Table 3. Cladding parameters and levels

View table

Table 3. Cladding parameters and levels

Variable	Notation	Unit	Value
Variable	Notation	Unit	Level -2	Level -1	Level 0	Level 1	Level 2
Laser power	LP	W	1200	1300	1400	1500	1600
Scanning speed	SS	mm·s^-1	4.0	4.5	5.0	5.5	6.0
Power feeding voltage	PFV	V	7.0	7.5	8.0	8.5	9.0
Defocusing amount	DA	mm	13	14	15	16	17

Table 4. Relationship between powder feeding voltage and powder feeding rate
View table
Table 4. Relationship between powder feeding voltage and powder feeding rate
Power feeding voltage /V 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Powder feeding rate /(g·min^-1) 6 7 9 10 11 13 16 17 18 21 22 24 24 25

Table 5. Central composite design and results

View table

Table 5. Central composite design and results

ExperimentNo.	Laserpower /W	Scanning speed /( mm·s^-1)	Power feedingvoltage /V	Defocusingamount /mm	Width-heightratio	Dilutionrate /%
1	1500	5.5	7.5	14	6.92	40.16
2	1300	4.5	8.5	14	2.87	26.85
3	1300	4.5	7.5	14	3.87	31.06
4	1200	5.0	8.0	15	7.10	34.36
5	1300	5.5	7.5	14	6.50	41.58
6	1400	5.0	8.0	13	3.98	34.80
7	1600	5.0	8.0	15	6.78	48.00
8	1400	6.0	8.0	15	9.95	47.57
9	1500	4.5	7.5	14	4.30	43.13
10	1400	5.0	8.0	15	6.67	46.20
11	1500	5.5	8.5	16	9.36	51.53
12	1400	5.0	8.0	15	7.31	50.29
13	1300	4.5	7.5	16	8.21	41.13
14	1400	5.0	7.0	15	9.88	49.81
15	1400	5.0	8.0	17	10.42	54.16
16	1500	4.5	8.5	16	7.16	51.38
17	1300	5.5	7.5	16	11.43	46.25
18	1400	5.0	9.0	15	8.23	44.48
19	1400	5.0	8.0	15	7.01	48.93
20	1300	5.5	8.5	14	5.35	35.94
21	1500	4.5	8.5	14	3.20	35.80
22	1300	4.5	8.5	16	6.26	41.75
23	1500	5.5	7.5	16	10.47	51.91
24	1500	4.5	7.5	16	8.99	54.65
25	1500	5.5	8.5	14	5.96	37.44
26	1400	5.0	8.0	15	6.22	51.98
27	1400	4.0	8.0	15	3.17	40.67
28	1400	5.0	8.0	15	5.89	47.71
29	1300	5.5	8.5	16	8.25	44.64
30	1400	5.0	8.0	15	5.50	49.90

Table 6. Variance analysis of width-height ratio

View table

Table 6. Variance analysis of width-height ratio

Source	Sum of squares	Mean square	F-value	P-value	Reliability
Model	144.77	36.19	84.13	<0.0001	Significant
S	45.21	45.21	105.09	<0.0001
V	10.11	10.11	23.51	<0.0001
D	80.81	80.81	187.86	<0.0001
V²	8.64	8.64	20.08	0.0001
Residual	10.75	0.43
Lack-of-fit value	8.39	0.43	0.88	0.6232	Not significant
Pure error	2.37	0.47
Total	155.53
R²=0.9309			$R_{PRED}^{2}$ =0.8861
$R_{ADJ}^{2}$ =0.9198			Signal-to-noise ratio: 30.154

Table 7. Variance analysis of dilution rate

View table

Table 7. Variance analysis of dilution rate

Source	Sum of squares	Mean square	F-value	P-value	Reliability
Model	1424.73	129.52	31.34	<0.0001	Significant
P	294.56	294.56	71.72	<0.0001
S	58.59	58.59	14.18	0.0014
V	51.63	51.63	12.49	0.0024
D	704.17	704.17	170.39	<0.0001
P×S	62.17	62.17	15.04	0.0011
P×D	13.32	13.32	3.22	0.0894
V×D	14.55	14.55	3.52	0.0769
P²	149.63	149.63	36.20	<0.0001
S²	70.27	70.27	17.00	0.0006
V²	19.56	19.56	4.73	0.0432
D²	62.59	62.59	15.15	0.0011
Residual	74.39	4.13
Lack-of-fit value	50.37	4.13	1.00	0.5456	Not significant
Pure error	20.69	4.14
Total	1499.12
R²=0.9504			$R_{PRED}^{2}$ =0.8462
$R_{ADJ}^{2}$ =0.9201			Signal-to-noise ratio: 19.478

Table 8. Optimization criteria

View table

Table 8. Optimization criteria

Parameter	Criterion	Limit
Parameter	Criterion	Low	Upper
Laser power	In range	1200 W	1600 W
Scanning speed	In range	1 mm·s^-1	3 mm·s^-1
Powder feeding voltage	In range	7 V	9 V
Defocusing amount	In range	13 mm	17 mm
W/H	In range	3	6
η	In range	30%	40%

Table 9. Optimization results and validation

View table

Table 9. Optimization results and validation

Parameter	Predicted result of model 1	Predicted result of model 2	Predicted result of model 3	Actual result
LP /W	1286.99	1281.53	1338	1290
SS /(mm·s^-1)	3.73	3.87	3.44	3.70
PFV /V	8.32	8.23	7.38	8.30
DA /mm	14.45	14.23	13.82	14.50
W /H	4.508	4.506	4.419	4.800
η /%	35.125	35.165	35.135	38.000
Desirability of model	0.863	0.861	0.830

Tools

Get Citation

Copy Citation Text

Lunxiang Li, Deqiang Zhang, Jinhua Li, Wenqiang Sun. Residual Stress Analysis and Shape Optimization of Laser Cladded Ni-Based Alloy Coatings[J]. Laser & Optoelectronics Progress, 2020, 57(17): 171405

Download Citation

EndNote(RIS)BibTex Plain Text

Set citation alerts for article

Save article for my favorites