Effect of total heat input on coaxiality of rotor shaft in laser cladding

Shirui Guo; Junhao Yu; Lujun Cui; Yinghao Cui; Xiaolei Li; Yongqian Chen; Bo Zheng

doi:10.1515/mt-2023-0152

Article

Effect of total heat input on coaxiality of rotor shaft in laser cladding

Shirui Guo
Shirui Guo is an associate professor and master supervisor of Zhongyuan University of Technology. At present, his research work mainly focuses on the laser additive manufacturing technology and laser surface modification technology.
, Junhao Yu
Junhao Yu received his master’s degree from Zhongyuan University of Technology. His research interests are mainly laser additive manufacturing technology and numerical simulation.
, Lujun Cui
Lujun Cui is a professor master’s supervisor, a co-supervisor for Ph.D. students, an expert in project evaluation for the Ministry of Science and Technology, an expert in peer review for the National Natural Science Foundation of China, and an expert in Master’s and Ph.D. thesis evaluation for the Ministry of Education. His research interests are the mechatronics and measurement control technology, laser manufacturing, and intelligent manufacturing.
, Yinghao Cui
Yinghao Cui is a master supervisor of Zhongyuan University of Technology. His research interests include metal laser cladding manufacturing, including surface cladding of important mechanical structures, structural integrity evaluation with defects, repair and numerical simulation.
, Xiaolei Li
Xiaolei Li is a master supervisor of Zhongyuan University of Technology. His research interests include metal laser cladding manufacturing, solidification, phase transition, microstructure and property regulation, material characterization technology of metal materials.
, Yongqian Chen
Yongqian Chen is a master supervisor of Zhongyuan University of Technology. His research interests include the optimization and design of high-energy lasers, diamond composite laser additive manufacturing, and ultrafast laser micro-nano technicians.
and Bo Zheng
Bo Zheng engages in Zhongyuan University of Technology. His research interests are mainly laser additive manufacturing technology.

Published/Copyright: January 8, 2024

Published by

Become an author with De Gruyter Brill

Submit Manuscript Author Information

From the journal Materials Testing Volume 66 Issue 2

Abstract

The total heat input by the laser directly affects the temperature distribution of the rotor shaft during the cladding process, and then affects its coaxiality. This article uses ANSYS for numerical simulation to study the effect of laser heat input on the deformation of the rotor shaft during laser cladding process. Simulate and analyze the temperature and stress fields inside the rotor shaft using thermal coupling. The results show that by changing the pitch, axial cladding width and laser irradiation duration to change the laser induced total heat input, a more uniform temperature distribution can be generated in the rotor shaft. The increase of temperature distribution uniformity can reduce the deformation of rotor shaft during cladding. Using a cladding equipment, iron based customized alloy powder was coated on the 45 steel rotor shaft for cladding experiments. And the mechanical properties and coaxiality of the rotor shaft after cladding were measured. The results showed that the hardness and wear resistance of the cladding layer were significantly improved compared to the substrate, and the changes in coaxiality of the rotor shaft were consistent with the simulation results, with relatively small errors. It is of great significance for repairing damaged rotor shafts.

Keywords: laser cladding; rotor shaft; numerical simulation; coaxiality; deformation

Corresponding author: Shirui Guo, Zhongyuan University of Technology, Zhengzhou, 450007, China; and Zhengzhou Key Laboratory of Laser Additive Manufacturing Technology, Zhengzhou, China, E-mail: laser@zut.edu.cn

Funding source: The Strength Enhancement Program for Advantageous Disciplines of Zhongyuan University of Technology â€œKey Discipline Teacher Support Program

Award Identifier / Grant number: No. GG202220

Funding source: Key Research and Development Project of Henan province

Award Identifier / Grant number: No:231111231200

Funding source: The Postgraduate Education Reform and Quality Improvement Project for School-Enterprise Joint Curriculum Construction of Zhongyuan University of Technology

Award Identifier / Grant number: No. LH202301

Funding source: Key Research and Development and Promotion Projects in Henan Province

Award Identifier / Grant number: No. 232102220051

Funding source: The Strength Enhancement Program for Advantageous Disciplines of Zhongyuan University of Technology â€œKey Discipline Development Program

Award Identifier / Grant number: No. FZ202204

Funding source: The Natural Science Foundation of Henan Province

Award Identifier / Grant number: No: 202300410514

Funding source: Key Scientific Research Project of Colleges and Universities in Henan Province

Award Identifier / Grant number: No: 24A460029

About the authors

Shirui Guo

Shirui Guo is an associate professor and master supervisor of Zhongyuan University of Technology. At present, his research work mainly focuses on the laser additive manufacturing technology and laser surface modification technology.

Junhao Yu

Junhao Yu received his master’s degree from Zhongyuan University of Technology. His research interests are mainly laser additive manufacturing technology and numerical simulation.

Lujun Cui

Lujun Cui is a professor master’s supervisor, a co-supervisor for Ph.D. students, an expert in project evaluation for the Ministry of Science and Technology, an expert in peer review for the National Natural Science Foundation of China, and an expert in Master’s and Ph.D. thesis evaluation for the Ministry of Education. His research interests are the mechatronics and measurement control technology, laser manufacturing, and intelligent manufacturing.

Yinghao Cui

Yinghao Cui is a master supervisor of Zhongyuan University of Technology. His research interests include metal laser cladding manufacturing, including surface cladding of important mechanical structures, structural integrity evaluation with defects, repair and numerical simulation.

Xiaolei Li

Xiaolei Li is a master supervisor of Zhongyuan University of Technology. His research interests include metal laser cladding manufacturing, solidification, phase transition, microstructure and property regulation, material characterization technology of metal materials.

Yongqian Chen

Yongqian Chen is a master supervisor of Zhongyuan University of Technology. His research interests include the optimization and design of high-energy lasers, diamond composite laser additive manufacturing, and ultrafast laser micro-nano technicians.

Bo Zheng

Bo Zheng engages in Zhongyuan University of Technology. His research interests are mainly laser additive manufacturing technology.

Research ethics: Not applicable.
Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.
Competing interests: The authors state no conflict of interest.
Research funding: This study was supported by the Key Research & Development and Promotion Projects in Henan Province (Grant No: 232102220051); Key Scientific Research Project of Colleges and Universities in Henan Province (Grant No: 24A460029); Key Research and Development Project of Henan province (Grant No: 231111231200); the Natural Science Foundation of Henan Province (Grant No: 202300410514); Project supported by the Strength Enhancement Program for Advantageous Disciplines of Zhongyuan University of Technology “Key Discipline Teacher Support Program” (Grant No: GG202220); and “Key Discipline Development Program” (Grant No: FZ202204); the Postgraduate Education Reform and Quality Improvement Project for Schoolenterprise Joint Curriculum Construction of Zhongyuan University of Technology (Grant No: LH202301).
Data availability: The raw data can be obtained on request from the corresponding author.

References

[1] Z. Liu, J. Gu, and J. Wang, “Research on the application of laser cladding technology in high-speed rotor shaft repair,” Appl. Laser, vol. 39, no. 05, pp. 750–755, 2019, https://doi.org/10.14128/j.cnki.al.20193905.750.Search in Google Scholar

[2] Z. Wang, W. Li, X. Du, and Y. Zhao, “Application status of laser cladding technology in remanufacturing of shaft parts,” Mech. Mater. Eng., vol. 4, no. 11, pp. 35–40, 2020, https://doi.org/10.11973/jxgccl202011007.Search in Google Scholar

[3] L. Xiao, Y. Ren, Q. Gao, Z. Li, and Z. Wang, “Research progress of laser cladding technology,” New Technol. Proc., vol. 4, no. 07, pp. 5–7, 2021, https://doi.org/10.16635/j.cnki.1003-5311.2021.07.002.Search in Google Scholar

[4] J. Zhang, S. Shi, Y. Gong, S. Yu, and T. Shi, “Research progress of laser cladding technology,” Surf. Technol., vol. 49, no. 10, pp. 1–11, 2020, https://doi.org/10.16490/j.cnki.issn.1001-3660.2020.10.001.Search in Google Scholar

[5] Y. Liu, Y. Ding, L. Yang, R. Sun, T. Zhang, and X. Yang, “Research and progress of laser cladding on engineering alloys: a review,” J. Manuf. Proc., vol. 66, pp. 341–363, 2021, https://doi.org/10.1016/j.jmapro.2021.03.061.Search in Google Scholar

[6] Q. Fu, Z. Jin, J. Tang, and L. Chen, “Analysis and control of deformation of gear shaft laser cladding shaft,” Elect. Welding Mach., vol. 42, no. 05, pp. 27–31, 2012, https://doi.org/10.3969/j.issn.1001-2303.2012.05.007.Search in Google Scholar

[7] Y. Huang, J. Zhao, and Z. Chen, “Research on deformation of multi position laser cladding of slender shaft parts,” Weld. Mach., vol. 49, no. 11, pp. 100–106, 2019.Search in Google Scholar

[8] Q. Zhang, P. Xu, G. Zha, Z. Ouyang, and D. He, “Numerical simulations of temperature and stress field of Fe–Mn–Si–Cr–Ni shape memory alloy coating synthesized bylasercladding,” Optik, vol. 242, 2021, Art. no. 167079, https://doi.org/10.1016/j.ijleo.2021.167079.Search in Google Scholar

[9] X. Geng, “Study on laser cladding process parameters of Fe-based alloy based on numerical simulation,” J. Phys.: Conf. Ser., vol. 1948, no. 1, p. 012231, 2021, https://doi.org/10.1088/1742-6596/1948/1/012231.Search in Google Scholar

[10] L. Chen, Y. Zhao, X. Chen, T. Yu, and P. Xu, “Repair of spline shaft by laser-cladding coarse TiC reinforced Ni-based coating: process, microstructure and properties,” Ceram. Int., vol. 47, pp. 30113–30128, 2021, https://doi.org/10.1016/j.ceramint.2021.07.189.Search in Google Scholar

[11] W. Zhang, J. Xue, Q. Nan, and L. Tong, “Study on the effect of laser process parameter rs on the cladding quality of camshaft,” IOP Conf. Ser.: Mater. Sci. Eng., vol. 1043, no. 2, p. 022069, 2021, https://doi.org/10.1088/1757-899X/1043/2/022069.Search in Google Scholar

[12] L. Shu, J. Wang, H. Bai, Y. He, and B. Wang, “Numerical simulation and test of laser cladding process of wear axis,” J. Mech. Eng., vol. 55, no. 9, pp. 217–223, 2019, https://doi.org/10.3901/JME.2019.09.217.Search in Google Scholar

[13] Q. Fu, Z. Jin, J. Tang, and L. Chen, “Numerical analysis of deformation of gear shaft laser cladding shaft,” Electromech. Eng., vol. 29, no. 5, pp. 497–500+511, 2012, https://doi.org/10.3969/j.issn.1001-4551.2012.05.002.Search in Google Scholar

[14] Y. Huang, W. Huang, H. Zhang, S. Yu, and J. Pan, “Numerical simulation of temperature field and deformation research during laser cladding repair of slender shaft parts,” Electromech Equip., vol. 34, no. 04, pp. 28–34+37, 2017, https://doi.org/10.16443/j.cnki.31-1420.2017.04.007.Search in Google Scholar

[15] Y. Pei, J. Wang, Q. Tan, D. Yuan, and F. Zhang, “An investigation on the bending straightening process of D-type cross section shaft,” Int. J. Mech. Sci., vols. 131–132, pp. 1082–1091, 2017, https://doi.org/10.1016/j.ijmecsci.2017.08.032.Search in Google Scholar

[16] T. Zhang, Q. Zhang, B. Yao, and B. Li, “Numerical simulation of temperature and stress fields in Ni based laser cladding layer on TC4 surface,” Prog. Laser Optoelectron., vol. 58, no. 03, pp. 220–228, 2021, https://doi.org/10.3788/LOP202158.0314003.Search in Google Scholar

[17] H. Liu, G. Yu, X. Hu, S. Li, and C. Zheng, “Three dimensional numerical simulation of transient temperature field and geometric morphology in powder feeding laser cladding,” China Laser, vol. 40, no. 12, pp. 84–91, 2013.10.3788/CJL201340.1203007Search in Google Scholar

[18] J. Gao, C. Wu, H. Yunbo, X. Xu, and L. Guo, “Numerical simulation and experimental investigation on three-dimensional modelling of single-track geometry and temperature evolution by laser cladding,” Opt. Laser. Technol., vol. 129, 2020, Art. no. 106287, https://doi.org/10.1016/j.optlastec.2020.106287.Search in Google Scholar

[19] F. Sun, Y. R. Li, Y.-X. Fu, W.-D. Tan, S. Feng, and M. Pang, “Study on the influence of laser power variation on the temperature Field of laser additive manufacturing Airport fuel supply pipe network,” Optik, vol. 221, 2020, Art. no. 165301, https://doi.org/10.1016/j.ijleo.2020.165301.Search in Google Scholar

[20] N. S. Bailey, C. Katinas, and Y. C. Shin, “Laser direct deposition of AISI H13 tool steel powder with numerical modeling of solid phase transformation, hardness, and residual stresses,” J. Mater. Process. Technol., vol. 247, pp. 223–233, 2017, https://doi.org/10.1016/j.jmatprotec.2017.04.020.Search in Google Scholar

[21] Z. Wang, E. Denlinger, P. Michaleris, A. Stoica, D. Ma, and A. Beese, “Residual stress mapping in Inconel 625 fabricated through additive manufacturing: method for neutron diffraction measurements to validate thermomechanical model predictions,” Mater. Des., vol. 113, pp. 169–177, 2016, https://doi.org/10.1016/j.matdes.2016.10.003.Search in Google Scholar

[22] K. Ren, Y. Chew, Y. F. Zhang, G. J. Bi, and J. Fuh, “Thermal analyses for optimal scanning pattern evaluation in laser aided additive manufacturing,” J. Mater. Process. Technol., vol. 271, pp. 178–188, 2019, https://doi.org/10.1016/j.jmatprotec.2019.03.029.Search in Google Scholar

[23] K. Ren, Y. Chew, J. Fuh, Y. Zhang, and G. Bi, “Thermo-mechanical analyses for optimized path planning in laser aided additive manufacturing processes,” Mater. Des., vol. 162, pp. 80–93, 2019, https://doi.org/10.1016/j.matdes.2018.11.014.Search in Google Scholar

Published Online: 2024-01-08

Published in Print: 2024-02-26

You are currently not able to access this content.

Articles in the same Issue

https://doi.org/10.1515/mt-2023-0152

Keywords for this article

laser cladding; rotor shaft; numerical simulation; coaxiality; deformation