Research Status and Development of Laser Cladding High Temperature Protective Coating

doi:10.11902/1005.4537.2023.160

Journal of Chinese Society for Corrosion and protection

2023, Vol. 43

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

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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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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

Received: 01 May 2023 32134.14.1005.4537.2023.160

ZTFLH:

TG174

Fund: National Natural Science Foundation of China(52101100);National Natural Science Foundation of China(62004117);General Project of Natural Science Research in Colleges and Universities of Jiangsu Province(21KJB430008);Qing Lan Project of Yangzhou University(2022);Cooperation Project between Yangzhou City and Yangzhou University(YZ2021153);National Key Research and Development Program(2022YFB3706600)

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

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Cite this article:

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.

URL:

https://www.jcscp.org/EN/10.11902/1005.4537.2023.160 OR https://www.jcscp.org/EN/Y2023/V43/I4/725

Fig.1 FE-SEM images of Cr₃C₂+Ni20Cr cladding coatings on Inconel 718 alloy at the laser frequencies of 12 Hz (a) and 20 Hz (b)^[19]

Fig.2 Microstructures of 30%TiC/Co-based alloy laser cladding layer on ductile cast iron: (a) near surface, (b) middle zone, (c) combining zone, (d) HAZ^[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

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