Microstructure Evaluation and High-Temperature Wear Performance of Hard Protective Layer Deposited on Titanium Alloy via Laser Metal Deposition

Al-Sayed, Samar Reda; Elgazzar, Haytham; Nofal, Adel

doi:10.1007/s12540-021-01160-x

Cited by 11 publications

(4 citation statements)

References 32 publications

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“…The microhardness is also affected by the fraction of the secondary carbides formed by solid-state precipitation such as W 2 C, TiC, Cr 7 C 3 , Cr 23 C 7 , and W 8 C 2 during the DED process, and the brittle intermetallic compounds like Co 25 Cr 25 and Co 3 W 3 C since such crystalized phases play a major role in increasing hardness values. This is in accord with previous work [32]. As the excessive hard intermetallic compounds benefit the hardness of the titanium substrate, it is also found that high residual stresses were generated as a result of such hard phases.…”

Section: Microhardness Distributionsupporting

confidence: 92%

Impact of laser process parameters in direct energy deposition on microstructure, layer characteristics, and microhardness of TC21 alloy

Elshaer

Elshazli

Al-Shatri

et al. 2022

Int J Adv Manuf Technol

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In the present study, layers consisting of 40% Stellite-6 and 60% WC were deposited on Ti-6Al-3Mo-2Sn-2Zr-2Nb-1.5Cr-0.1Si (TC21) alloy by means of direct energy deposition (DED) technology aiming to improve the microstructure and microhardness. Five powder feeding rates ranging from 20 to 100 ɡ min−1 were applied using CW fiber-coupled diode laser with 4 kW output power. The deposited layers were analyzed via scanning electron microscopy (SEM), energy-dispersive X-ray analysis (EDX), and X-ray diffractometry (XRD). The results show that WC particles are dispersed in a heterogeneous manner in the deposition zone, especially at the rates 20, 40, and 60 ɡ min−1. In addition, microcracks appeared in the interface zone particularly at 100 ɡ min−1 due to the higher induced residual stresses caused by the difference in the coefficient of thermal expansion between Stellite-6, WC particles, and TC21 substrate alloy. Several complex carbides and intermetallic compounds such as W2C, TiC, Cr7C3, Co3W3C, and Co25Cr25W8C2 were detected in the deposited layers depending on the powder feeding rate. With further increase in the powder feeding rate, the fractions of W2C and the bulk (unmelted) WC particles were increased and that of the TiC particle was reduced correspondingly due to the thermal diffusion. The layer thickness increased from 1.3 to 2.7 mm when the powder feeding rate increased from 40 to 100 ɡ min−1, while the dilution ratio decreased from 23 to 5.3% as a result of the thermal diffusion of the laser energy. The microhardness of the composite was found to be three times higher than that recorded for the TC21 substrate (1020 vs. 340 HV0.05). The results revealed that the best homogeneous microstructure with the highest microhardness was achieved at the powder feeding rate of 100 ɡ min−1 whereas microcracks free layers were accomplished at 40 ɡ min−1.

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Section: Microhardness Distributionsupporting

confidence: 92%

Impact of laser process parameters in direct energy deposition on microstructure, layer characteristics, and microhardness of TC21 alloy

Elshaer

Elshazli

Al-Shatri

et al. 2022

Int J Adv Manuf Technol

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“…This could be related to the higher density of the WC particle (15.63 g.cm À3 ) than that of Ni-based alloy (8.9 g cm À3 ) which leads to a higher flow of WC particles than the Ni particles from the deposited powder. [14] This behavior can confirm the increase in the powder flow rate and the concentration of the WC particles quantity in the melt pool of the deposited layers. Another observation is that the WC particles' edges were fragmented and diffused into the solid solution of the metal matrix forming new phases.…”

Section: A Clad Layer Characterizationsupporting

confidence: 53%

“…This may be attributed to the volume fraction together with the size of the secondary carbides, formed by solid-state precipitation of W 2 C and TiC. [14] The two misclassification results were attributed to the samples with microhardness values of 1000 HV 0.1 and 1400 HV 0.1 which related to the clad layers formed at powder feeding rates of 40 and 60 g min À1 , respectively. The explanation was gained from the SEM at higher magnification (Figure 11).…”

Section: Microhardness Estimationmentioning

confidence: 99%

“…Alloys such as Co, Mo, Ni, and Fe-based alloys are predominant, particularly Ni-based alloys, to provide better high-temperature, corrosion, wear resistance, and ease of bonding with the titanium substrate due to the close of their properties. [12] Nickel-based alloys are prone to tribological attack due to their ductile matrix, accordingly, Inconel alloys, [13] and various ceramics [14,15] are widely used as feedstock materials. Lately, ceramics like carbides (TiC, [16] SiC [17] ), nitrides (TiN, [18] BN [19] ) and oxides [20] were deposited on titanium alloys.…”

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Novel Surface Topography and Microhardness Characterization of Laser Clad Layer on TC4 Titanium Alloy Using Laser-Induced Breakdown Spectroscopy and Machine Learning

Al-Sayed

Samad²,

Mohamed³

et al. 2022

Metall Mater Trans A

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This study was performed to characterize surface topography and microhardness of 40 wt pct NiCrBSiC-60 wt pct WC hard coating on TC4 titanium after coaxial laser cladding via Laser Induced Breakdown Spectroscopy (LIBS) and machine learning. The high content of the hard WC particles is accomplished to enhance the abrasion wear resistance of such alloy. Various powder feeding rates were carried out during laser cladding process. The energy-dispersive X-ray analysis assured that W content in the metal matrix notably increased from 26.19 to 53.49 pct while the Ti content decreased from about 15.16 to 0.46 pct for the clad layer processed at 20 and 60 g min−1, respectively. The LIBS measurements successfully estimated such elements’ concentration as well as the clad layers' topography indicating that the effect of material matrix is a crucial challenge. Therefore, canonical correlation analysis and Belsley collinearity diagnostics were established to identify the essential emission lines from the whole spectra. Then, an optimized adaptive boosted random forest classifier was developed for microhardness investigation, with accuracy, sensitivity, and F1 score values of 0.9667. The results, confirmed by the metallurgical study, clarified that most of the titanium and tungsten emission lines have a significant impact on the surface topography as well as the microhardness values. The misclassification was attributed to the matrix effect such that the samples processed at 40 and 60 g min−1 were comparable in microstructure and chemical characterization unlike the one processed at 20 g min−1. Vickers microhardness of the metal matrix coating increased with the increase in the powder feeding rate, which is assured by the quantitative classification model. Graphical Abstract

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Experimental Study and Thermo-Mechanical Simulation of Friction Surfacing Treated A390 Aluminum Alloy

Bararpour,

Jamshidi Aval,

Jamaati

et al. 2023

Met. Mater. Int.

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Microstructure Evaluation and High-Temperature Wear Performance of Hard Protective Layer Deposited on Titanium Alloy via Laser Metal Deposition

Cited by 11 publications

References 32 publications

Impact of laser process parameters in direct energy deposition on microstructure, layer characteristics, and microhardness of TC21 alloy

Impact of laser process parameters in direct energy deposition on microstructure, layer characteristics, and microhardness of TC21 alloy

Novel Surface Topography and Microhardness Characterization of Laser Clad Layer on TC4 Titanium Alloy Using Laser-Induced Breakdown Spectroscopy and Machine Learning

Experimental Study and Thermo-Mechanical Simulation of Friction Surfacing Treated A390 Aluminum Alloy

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