激光熔覆高温防护涂层研究现状及发展方向

doi:10.11902/1005.4537.2023.160

中国腐蚀与防护学报

2023, Vol. 43

Issue (4): 725-736 CSTR: 32134.14.1005.4537.2023.160 DOI: 10.11902/1005.4537.2023.160

中国腐蚀与防护学会杰出青年成就奖论文专栏

本期目录 | 过刊浏览

激光熔覆高温防护涂层研究现状及发展方向

吴多利¹, 吴昊天¹, 孙珲²(

), 史建军³, 魏新龙¹, 张超¹(

)

^1.扬州大学机械工程学院扬州 225127
^2.山东大学空间科学与物理学院威海 264209
^3.南京工程学院工业中心南京 211167

Research Status and Development of Laser Cladding High Temperature Protective Coating

WU Duoli¹, WU Haotian¹, SUN Hui²(

), SHI Jianjun³, WEI Xinlong¹, ZHANG Chao¹(

)

^1.College of Mechanical Engineering, Yangzhou University, Yangzhou 225127, China
^2.School of Space Science and Physics, Shandong University, Weihai 264209, China
^3.Industrial Center, Nanjing Institute of Technology, Nanjing 211167, China

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摘要:

本文对航空航天、汽车工业和火力发电等领域热端部件高温防护涂层的研究现状和成果进行了总结，分析了激光熔覆制备涂层可能产生的缺陷种类及形成原因，最后指出激光熔覆技术未来发展所面临的困难和挑战，并对该技术的发展方向和趋势进行展望。

关键词 ：激光熔覆, 高温防护, 熔覆裂纹, 研究现状, 耐腐蚀

Abstract：

In aerospace, automobile, power generation and other industrial fields, many crucial hot end components such as aviation engine, automobile engine, coal (oil, gas) boiler and turbine blades, valve components, superheater tube etc. are servicing in high temperature-, high pressure-, corrosion-environments for a long time, thus which suffered easily from surface oxidation- or corrosion-damages. The preparation of high temperature protective coating on the surface of those parts is an important technical means to improve their service performance. The mechanical bonding strength of the coating prepared by thermal spraying is not high, and the coating is usually porous. Under the condition of high temperature, corrosion is easy to occur through pores, and even penetrate the coating onto the matrix, which is not conducive to the high temperature corrosion protection of the workpiece. Laser cladding technology is an advanced and rapidly developing surface modification technology, which can make a very strong metallurgical combination for the cladding materials with the matrix, but also has the advantages of coatings with high compactness, low dilution rate, and environmentally friendly etc. This paper first summarizes the research status and achievements of high-temperature protective coatings for hot-end components in industries such as aerospace, automotive, and power generation. Secondly, it analyzes the types of defects that may occur during laser cladding for coating preparation and the cause for their formation. Finally, it points out the difficulties and challenges faced by the future development of laser cladding technology and prospects for its development direction and trend.

Key words： laser cladding high temperature protection laser cladding crack research status corrosion resistance

收稿日期: 2023-05-01 32134.14.1005.4537.2023.160

ZTFLH:

TG174

基金资助:国家自然科学基金(52101100);国家自然科学基金(62004117);江苏省高校自然科学基金(21KJB430008);扬州大学青蓝工程项目(2022);扬州市校合作项目(YZ2021153);国家重点研发计划(2022YFB3706600)

通讯作者: 孙珲，E-mail: huisun@sdu.edu.cn，研究方向为功能涂层与器件;张超，E-mail: zhangc@yzu.edu.cn，研究方向为热喷涂结构与功能涂层

Corresponding author: SUN Hui, E-mail: huisun@sdu.edu.cn;ZHANG Chao, E-mail: zhangc@yzu.edu.cn

作者简介: 吴多利，男，1987年生，博士，副教授
孙珲，1985 年出生，2016 年毕业于法国UTBM大学，获博士学位。随后在法国CNRS，FEMTO-ST实验室从事真空镀膜方面的研究。现就职于山东大学，副研究员，博士生导师，系主任。孙珲博士主要从事半导体薄膜的光电力学性质的研究。针对p 型透明导电材料在加工使用过程中耐腐蚀性差、膜层易脱落及其p 型空穴载流子局域性强的问题，通过局域相变、应力调控等方式对膜层的附着强度和耐磨耐蚀性能进行优化；通过价带修饰、位错演化等途径对半导体薄膜的缺陷形态和载流子产生输运行为进行有效调控，显著提升材料的光电性能和使用寿命。主持国家自然科学基金、装备预研教育部联合基金等多项国家及省部级项目。兼任中国腐蚀与防护学会理事、中国机械学会表面工程分会委员以及多个期刊的青年编委。获得山东大学青年学者未来计划人才项目资助。以第一或通讯作者发表SCI论文44 篇，其中，中科院TOP期刊论文27 篇，1 篇Invited feature article；申请发明专利12 项，授权8 项。曾获得法国优秀博士论文，以第一完成人获得中国腐蚀与防护学会科学技术一等奖1 项。2023年获得中国腐蚀与防护学会杰出青年成就奖。

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引用本文:

吴多利, 吴昊天, 孙珲, 史建军, 魏新龙, 张超. 激光熔覆高温防护涂层研究现状及发展方向[J]. 中国腐蚀与防护学报, 2023, 43(4): 725-736.
WU Duoli, WU Haotian, SUN Hui, SHI Jianjun, WEI Xinlong, ZHANG Chao. Research Status and Development of Laser Cladding High Temperature Protective Coating. Journal of Chinese Society for Corrosion and protection, 2023, 43(4): 725-736.

链接本文:

https://www.jcscp.org/CN/10.11902/1005.4537.2023.160 或 https://www.jcscp.org/CN/Y2023/V43/I4/725

图1 在Inconel 718合金表面12和20 Hz激光频率下熔覆的Cr3C2+Ni20Cr涂层表面的FE-SEM表面像[19]

图2 球墨铸铁表面30%TiC/钴基合金激光熔覆横截面组织形貌[29]

Laser cladding mode (Preset or feed power)	Equipment Type	Composition of Substrate (Sub) and powder material (Pow)	Laser cladding parameters:laser power (P), Scanning velocity (V), Powder feed rate (R)	Cladding layer parameters: Weld width (W), Weld height (H), Dilution rates (η)	Cladding layer phase composition	Properties of cladding layer	Application scenarios
Coaxial powder feeding	YLS-400 fiber laser	Sub: K418 alloy Pow: Inconel 718	P: 1.2 kW V: 300 mm/min R: 25 g/min	W: 1.414 mm H: 1.537 mm η: 10.09%	Laves phase, γ" phase and MC type carbide were precipitated at the bottom of the cladding layer.	Hot-corrosion resistant; Thermal shock resistant	Repair of turbine blades of aeroengines
	YLS-3000 fiber laser	Sub: K465 alloy Pow: nickel-based alloy	P: 2.4 kW V: 360 mm/min R: 12 g/min	W: 2.86 mm H: 0.72 mm η: 0.27 mm	γ phase, γ' phase, granular carbide and chain carbide in the cladding layer.	Hot-corrosion resistant	Repair of turbine blades of aeroengines
	IPG-YLS-2000-TR fiber laser	Sub: IN718 alloy Pow: 30%WC + Inconel 718	P: 1.5 kW V: 450 mm/min R: 12 g/min	η: 18.51%	(Fe, Ni) solid solution phase, Fe₃Ni₂ phase, (Fe, Cr, Ni)C phase, Ni₁₇W₃ phase, WC ceramic particle phase, W₂C phase, Fe₄W₂C phase and Cr₄Ni₁₅W phase in the cladding layer.	High hardness; Wear resistant; Heat resistant	Surface strengthening of turbine disc, combustion chamber and other components of aeroengine
	CO₂ laser machine	Sub: K438 alloy Pow: CoNiCrAlY+ 25%Al₂O₃	P: 2.5 kW V: 240 mm/min R: 0.5 g/min	-	There are α-Co phase, α-Al₂O₃ phase, NiO phase, Cr₂O₃ phase, γ-(Ni, Cr) phase, γ'-Ni₃Al phase and (Co, Ni)(Al, Cr)₂O₄ phase in the cladding layer.	High temperature oxidation resistant
	FL-Dlight3-2000 semiconductor laser unit	Sub: 304 steel Pow: Ni60AA	P: 2.5 kW V: 240 mm/min R: 18 g/min	W: 14.85 mm H: 1.68 mm η: 13.49%	γ-(Ni, Fe) solid solution phase, FeNi₃ ductile phase and Cr₂₃C₆ carbide in the cladding layer.	High hardness; Wear resistant; Corrosion resistant	Surface strengthening and repair of automotive engine valve components
	IPG fiber laser	Sub: 2Cr25Ni20 steel Pow: Inconel 718	P: 1.4 kW V: 600 mm/min R: 1.8 r/min	-	Precipitated phase of cladding layer is Laves phase and a small amount of carbide.	High hardness; Wear resistant;	Surface strengthening of feed inlet rotating shaft in steel mill
	LDF400-2000 Fiber coupled semiconductor laser	Sub: Inconel718 alloy Pow：Inconel 939	P: 0.9 kW V: 240 mm/min R: 14 g/min	η: 24.2 %	Physical phases in the cladding layer include γ phase matrix, MC type carbide and a small amount of γ' phase.	High hardness; Corrosion resistant	Repair of gas turbine blades
Coaxial powder feeding	LDF4000-100 semiconductor laser unit	Sub: 304 steel Pow: NiCoCrAlY	P: 1.5 kW V: 600 mm/min R: 4.5 g/min	W: 3.6 mm H: 0.4 mm η: 57.4%	Phases in the cladding layer include γ/γ' phase, β phase and β-NiAl phase.	Wear resistant; High temperature oxidation resistant	Coating thermal protection of steam turbine hot components
Coaxial powder feeding	LDF4000-100 semiconductor laser unit	Sub: 316 steel Pow: FeCrAlSi	P: 1.6 kW V: 420 mm/min R: 5.4 g/min	W: 3.494 mm H: 0.588 mm η: 40.4%	Cladding layer consists of Fe-Cr solid solution phase and AlFe intermetallic compound.	High hardness; Wear resistant; Hot-corrosion resistant;	Surface modification of boiler pipe in power plant
Powder presetting	GS-TFL-6000 CO₂laser machine	Sub: TC6 alloy Pow: Ti-Al-20Cr	P: 4.1 kW V: 350 mm/min	η: <8%	Cladding layer is mainly composed of matrix structure and a large amount of silver-white material without obvious segregation phenomenon.	High temperature oxidation resistant	Repair of aero-engine compressor disc and blade
	LDF-4000-100 semiconductor laser unit	Sub: TC4 alloy Pow: CoCrFeNi₂V_0.5Ti_0.5	P: 0.8 kW V: 300 mm/min	-	Physical phases in the cladding layer include BCC phase, (Ni, Co)Ti₂ phase and α-Ti enriched phase.	High hardness; Wear resistant;	Surface modification of hot end components in aero-engines and automotive engines
	LDF-4000-100 semiconductor laser unit	Sub: TC4 alloy Pow: CoCrFeNi₂Mo_0.5	P: 1 kW V: 300 mm/min		Phases in the cladding layer include BCC phase, (Ni, Co)Ti₂ phase, α-Ti phase and FeCrMo type σ phase.
	Lasertel 8 kW semiconductor laser unit	Sub: TC4 alloy Pow: TC4+10%hBN	P: 4 kW V: 900 mm/min	-	Cladding layer consists of TiB phase and TiN phase distributed in α-Ti matrix
	Lasertel 8 kW semiconductor laser unit	Sub: TC4 alloy Pow: TC4+10%Ni/B₄C	P: 4 kW V: 480 mm/min		Cladding layer is composed of NiTi₂ phase, dendritic phase, TiB phase, TiC phase, TiB₂ and incomplete decomposed B₄C embedded in α-Ti matrix.
	GS-TEL-6000A Multi-mode cross-flow CO₂ laser	Sub: TC4 alloy Pow: AlMoNbTiV	P: 3.7 kW V: 600 mm/min	-	Cladding layer is mainly composed of BCC phase and a small amount of TiAl intermetallic compounds.	High temperature oxidation resistant
	LWS-1000 Nd: YAG laser	Sub: 304 steel Pow: FeCoCuAlNiNb_0.5	P: 0.2 kW V: 420 mm/min	η: 15%	Phase in cladding layer includes BCC phase, FCC phase and Laves phase.	Wear resistant; Corrosion resistant	Surface strengthening and repair of automotive engine valve components

表1 激光熔覆在高温防护涂层方面的应用实例

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