Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method

doi:10.1007/s11465-016-0397-7

Front. Mech. Eng.

2016, Vol. 11

Issue (3) : 242-249 https://doi.org/10.1007/s11465-016-0397-7

RESEARCH ARTICLE

Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method

Zilin HUANG¹,Gang WANG^2,^*(

),Shaopeng WEI²,Changhong LI³,Yiming RONG⁴

¹. School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University, Beijing 100044, China; Beijing Key Laboratory of Precision/Ultra-precision Manufacturing Equipments and Control, Tsinghua University, Beijing 100084, China
². Beijing Key Laboratory of Precision/Ultra-precision Manufacturing Equipments and Control, Tsinghua University, Beijing 100084, China
³. School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University, Beijing 100044, China
⁴. Beijing Key Laboratory of Precision/Ultra-precision Manufacturing Equipments and Control, Tsinghua University, Beijing 100084, China; Mechanical and Energy Engineering Department, South University of Science and Technology of China, Shenzhen 518055, China

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Abstract

Laser hot wire cladding, with the prominent features of low heat input, high energy efficiency, and high precision, is widely used for remanufacturing metal parts. The cladding process, however, needs to be improved by using a quantitative method. In this work, volumetric defect ratio was proposed as the criterion to describe the integrity of forming quality for cladding layers. Laser deposition experiments with FV520B, one of martensitic stainless steels, were designed by using the Taguchi method. Four process variables, namely, laser power (P), scanning speed (V_s), wire feed rate (V_f), and wire current (I), were optimized based on the analysis of signal-to-noise (S/N) ratio. Metallurgic observation of cladding layer was conducted to compare the forming quality and to validate the analysis method. A stable and continuous process with the optimum parameter combination produced uniform microstructure with minimal defects and cracks, which resulted in a good metallurgical bonding interface.

Keywords process optimization Taguchi method signal-to-noise (S/N) ratio volumetric defect ratio laser hot wire cladding

Corresponding Author(s): Gang WANG

Online First Date: 26 July 2016 Issue Date: 31 August 2016

Cite this article:

Zilin HUANG,Gang WANG,Shaopeng WEI, et al. Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method[J]. Front. Mech. Eng., 2016, 11(3): 242-249.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-016-0397-7
https://academic.hep.com.cn/fme/EN/Y2016/V11/I3/242

Tab.1 Chemical composition of FV520B steel

Fig.1 Experimental equipment of the laser hot wire cladding process

Fig.2 Morphology of cladding layer with three transfer modes

Fig.3 3D scanning of laser cladding layer and positions of the cross section

Tab.2 Design factor and levels

Tab.3 Experimental results for volumetric defect ratio and corresponding S/N ratio

Tab.4 Response table for S/N ratio

Fig.4 S/N response for volumetric defect ratio. (a) Laser power; (b) scanning speed; (c) wire feed rate; (d) wire current

Fig.5 Cladding morphology under three typical wire transfer modes. (a) Fusing transfer; (b) scratch transfer; (c) continuous transfer

Fig.6 (a) Incomplete fusion in singe-layer cladding; partial enlargements of (b) Point 1, (c) Point 2, and (d) Point 3, zone of interface between the cladding and substrate

Fig.7 Local incomplete fusion between substrate and deposition layer

Fig.8 Flat cladding layer caused by a low wire feed rate

Fig.9 (a) Microstructure of single-pass layer with optimum process parameters; partial enlargements of (b) Point 1 and (c) Point 2 zone of clad layer and substrate

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