Microstructure Controlling and Properties of Laser Cladded High Strength and High Toughness Fe-Based Coatings
FENG Kai1,2,3, GUO Yanbing4, FENG Yulei1,2,3, YAO Chengwu1,2,3, ZHU Yanyan1,2,3, ZHANG Qunli5, LI Zhuguo1,2,3()
1.School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China 2.Shanghai Key Laboratory of Materials Laser Processing and Modification, Shanghai Jiao Tong University, Shanghai 200240, China 3.Collaborative Innovation Center for Advanced Ship and Deep-Sea Exploration, Shanghai 200240, China 4.School of Materials Science, Shanghai DianJi University, Shanghai 201306, China 5.Institute of Laser Advanced Manufacturing, Zhejiang University of Technology, Hangzhou 310014, China
Cite this article:
FENG Kai, GUO Yanbing, FENG Yulei, YAO Chengwu, ZHU Yanyan, ZHANG Qunli, LI Zhuguo. Microstructure Controlling and Properties of Laser Cladded High Strength and High Toughness Fe-Based Coatings. Acta Metall Sin, 2022, 58(4): 513-528.
Laser cladding is a powerful surface strengthening technology that combines with high precision forming and low substrate damage to endow components with high surface performance. Fe-based coatings have been widely used in the surface engineering of many mechanical components. As the demand for higher performance and longer service life for components increases, the design and fabrication of new laser cladded coatings are expected to improve. This paper reviews recent research results of our team on laser cladding of novel Fe-based coatings, such as nano-bainite Fe-based coating, ultra-fine eutectic Fe-based coating, particle reinforced martensite coating, and high-hardness amorphous Fe-based coating. The study results are presented from the perspectives of the design, microstructure, and mechanical properties of these novel coating materials.
Fig.1 Nano bainitic microstructures in the coatings obtained at different isothermal temperatures of 200oC for 24 h (a), 250oC for 16 h (b), and 300oC for 8 h (c)[46], and retained austenite generated mechanism (d)[48]
Fig.2 The pole figures and inverse pole figures (IPFs) of nano bainitic ferrite in the coatings obtained at different isothermal temperatures[49]
Fig.3 TEM images of microstructure and selected area electron diffraction (SAED) patterns of nano bainite obtained at different isothermal temperatures[49] (a) 300oC (b) 250oC (c) 200oC
Fig.4 Kinetic curves of nano bainitic transformation under different isothermal temperatures
Fig.5 The mechanical properties of the laser cladded nano bainitic coatings under different isothermal temperatures (HAZ—heat affected zone) (a) Vickers hardness (b) tensile strength
Fig.6 Microstructures of the coatings[60] (a) macrograph of the single-pass coating (b) macrograph of the multi-pass coating (c) bottom of the coating (d) center of the coating (e) magnification of Fig.6d (f) phase maps of the coating
Fig.7 TEM images of the different position of coating[60] (a) bright-field image and corresponding SAED pattern of matrix in the coating (b, c) bright-field image of eutectic in the coating (b) and corresponding SAED pattern of γ-Fe (c) (d) magnification of Fig.7a (e) magnification of Fig.7b (f) SAED pattern of M3(C, B)
Fig.8 Residual stress distributions with depth of the single-pass coating (a) and the multi-pass coating (b)[60]
Fig.9 The hardness distributions of the coatings (Unit:HV; inset is the SEM image of the nano indentation tested area)[60]
Fig.10 The nanohardnesses and corresponding SEM images of the nanoindentation morphologies[60]
Fig.11 The wear resistance of the coating and substrate[60] (a) friction coefficient (b) average wear rate and friction coefficient
Compound
Hardness / HV
Wear rate
10-5 mm3·N-1·m-1
Present
850
0.92
M4
953
2.1
HS-30
925
2.3
M2
928
3.1
HS-23
853
3.9
WR6
864
4.4
WR6 + VC
949
5.1
AISI 420
715
8.5
H13
697
12.9
AISI 431
729
20.6
Table 1 Hardness and wear resistance of the traditional tool steel coating and present coating[68]
Fig.12 Microstructures of coating and XRD spectrum[73] (a) macrostructure of the coating (b) OM image of the coating (c) high magnification of the area in Fig.12b (d, e) high magnification of the area in Fig.12c (d) and XRD spectrum (e)
Fig.13 Microstructures of cladding layer[73] (a) TEM image (b) TEM image in the interdendritic region (Inset shows the SAED pattern of blocky carbide) (c) magnification of the region plotted by the rectangular mark in Fig.13b (Inset shows the SAED pattern of retained austenite) (d) local magnification of Fig.13a
Fig.14 Hardness distribution of the coatings[74]
Fig.15 Stress-strain curve (a) and fracture surface morphology (b) of coating (Point A, yield strength; point B, rupture)[74]
Fig.16 XRD spectra of laser cladded coating with different cladding rates[76]
Fig.17 Cross-sectional OM images of the coating with different laser scanning rates (a), and cross-sectional images after the Image Segmentation Software processing (b)[76]
Fig.18 XRD analyses of the coating at different distances from the interface of coating/substrate[77] (a) SEM image of coatings (b) XRD spectra at different depths (c) fusion line between coating and substrate
Distance to fusion line / mm
Phases composition
Amorphous percentage / %
Grain size / nm
0.570
Fe2B, FeCo
76.8
~19.9
0.503
Amorphous, NbC
96.2
29.9-32.0
0.327
Amorphous, NbC
95.7
29.5-31.0
0.015
FeCo
11.9
~6.4
Substrate
Fe
0
~22.6
Table 2 Amorphous fraction and grain size in different regions of the coating[76]
Fig.19 Microhardness curve along the cross-section of the coating (a) and SEM image of the microhardness indentation (b)[80]
Fig.20 Friction coefficient-time (μ-t) curves of the layer III, layer I and II, and substrate[76]
Region
Average friction
force / N
Wear mass
loss / g
Friction coefficient
Range
Average
Relative wear
Layer III
206.47
0.003
0.0974-0.1151
0.10486
0.28
Layer I and II
206.56
0.011
0.2285-0.2536
0.24412
0.66
Substrate
204.21
0.055
0.3424-0.3857
0.36816
1
Table 3 Statistic results on friction force, wear mass loss, and friction coefficient during wear process[76]
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