3D Thermal Model of Laser Surface Glazing for Ti6Al4V alloy

t: Ti6Al4V alloy plays a significant role in the biomedical applications such as bioimplants for its excellent biocompatibility. Its usage can be further extended by improving the surface hardness and wear resistance. In this respect, laser surface glazing (LSG), an advanced surface modification technique, is very useful which can produce thin hardened surface layer and strong metallurgical bonding. Investigation of temporal and spatial temperature distributions of laser glazed surface of materials are essential because temperature plays significant role in achieving required surface properties. Therefore, in this study, a 3D Finite element analysis has been developed to perform transient thermal analysis of LSG for Ti64 alloy. The model investigated temperature distribution, depth of modified zone and heating and cooling. The results show that the peak temperature is attained 2095 K for 300 W laser power, 0.2 mm beam width and 0.15 ms residence time. Since this temperature is above the melting point (1933 K) of Ti64 alloy, the melt depth is calculated 22.5 μm. Furthermore, from the simulation results, the average heating and cooling rates are estimated 1.19×107 Ks-1 and 2.71×106 Ks-1 respectively which indicate the presence of hard phases in the modified zone

A One-dimensional Analysis of the Distribution of Temperature, Stress and Strain in the co-axial Laser Cladding Process

The co-axial Laser Cladding (LC) is one of the most advanced surface treatment processes where generally a superior powder or wire material is deposited on the substrate to improve surface properties by using laser heat source. In this work, a physical model of the clad and the substrate has been presented. An attempt has been made to describe the simplified relation of temperature, stress and strain with time by using the established theoretical knowledge of generation of stress and strain after thermal treatment. The simplified relation of temperature, stress and strain with time has been explained with the help of schematic diagrams. The finding of this study will help to understand the temperature, stress and strain behaviour with time in the Laser Cladding process

Progress in Numerical Simulation of the Laser Cladding Process

Laser Cladding is one of the developing manufacturing techniques used for diverse applications such as coating, repairing and prototyping. Complex processing phenomena and the formation and growth of thin clad of few micrometers to millimeters range in most cases are yet to be fully understood. However, in recent past, several numerical models have been reported to get some understanding of physical, dynamic and metallurgical phenomena of this process. This article reviews the progress of numerical simulations spanning over three distinct stages of the process to model powder flow dynamics, melt pool and clad properties. For each stage, the governing equations, the effect of process variables and experimental validation techniques have been discussed. Specifically, we have outlined some of the underlying assumptions in the current numerical models which can act as pointers for further improvement of the existing numerical models. Authors recommend that numerical simulation results have to be complemented with experimental results to achieve better clad properties

Laser Surface Modification of H13 Die Steel using Different Laser Spot Sizes

This paper presents a laser surface modification process of AISI H13 tool steel using three sizes of laser spot with an aim to achieve reduced grain size and surface roughness. A Rofin DC'015 diffusion'cooled CO2 slab laser was used to process AISI H13 tool steel samples. Samples of 10 mm diameter were sectioned to 100 mm length in order to process a predefined circumferential area. The parameters selected for examination were laser peak power, overlap percentage and pulse repetition frequency (PRF). Metallographic study and image analysis were done to measure the grain size and the modified surface roughness was measured using two'dimensional surface profilometer. From metallographic study, the smallest grain sizes measured by laser modified surface were between 0.51 3m and 2.54 3m. The minimum surface roughness, Ra, recorded was 3.0 3m. This surface roughness of the modified die steel is similar to the surface quality of cast products. The grain size correlation with hardness followed the findings correlate with Hall'Petch relationship. The potential found for increase in surface hardness represents an important method to sustain tooling life

Impacts of Salinity on Soil Properties of Coastal Areas in Bangladesh

Sea level rise is a growing threat for the coastal regions of Bangladesh. It is one of the most densely populated countries of the world where 28% of the population are living in the coastal area. Bangladesh has already been affected by sea level rise through land erosion, salinity intrusion and loss in biodiversity. Saline soil has a detrimental effect upon soil physical and chemical properties. The dominant soil textural classes that occur in the saline areas of these regions are silty clay. In both of the soils pH value of the surface horizon is slightly lower than those of the subsoil and sub stratums. Cation Exchange Capacity (CEC) of all these soils varies from 12.0 to 27.6 meq/100 g soil expressing medium to high status. The organic matter content is medium to high at Asasuni and pretty low at Kalapara. In both areas, nutrient deficiencies of total nitrogen, phosphorous and potassium were quite dominant but sulphur was high. Exchangeable sodium, potassium, calcium and magnesium were in high level. The dominant water soluble cations were Na+, Ca2+, Mg2+ and K+ and anions Cl- and SO4 2-.The amount of accumulated salt was found higher at the surface and decreases with depth

Laser Micro-Processing Of Amorphous And Partially Crystalline cu45Zr48Al7 Alloy

This paper presents a microstructural study of laser micro-processed high-purity Cu45Zr48Al7 alloys prepared by arc melting and Cu-mould casting. Microprocessing of the Cu45Zr48Al7 alloy was performed using a Rofin DC-015 diffusion-cooled CO2 slab laser system with 10.6-µm wavelength. The laser was defocused to a spot size of 0.2 mm on the sample surface. The laser parameters were set to give 300- and 350-Wpeak power, 30% duty cycle and a 3000-Hz laser pulse repetition frequency (PRF). About 100-micrometer-wide channels were scribed on the surfaces of disk-shaped amorphous and partially crystalline samples at traverse speeds of 500 and 5000 mm/min. These channels were analysed using scanning electron microscopy (SEM) and 2D stylus profilometry. The metallographic study and profile of these processed regions are discussed in terms of the applied laser processing parameters. The SEM micrographs showed that striation marks developed at the edge and inside these regions as a result of the laser processing. The results from this work showed that microscale features can be produced on the surface of amorphous Cu–Zr–Al alloys by CO2 laser processing

Thermo-mechanical modelling to evaluate residual stress and material compatibility of laser cladding process depositing similar and dissimilar material on Ti6Al4V alloy

The formation of residual stresses due to thermo-mechanical effect and microstructural transformation in the Laser Cladding process predominantly affects the final product integrity and service life. A 3D finite element transient thermo-mechanical model has been developed to predict thermal profile and residual stress distribution for repair application of Ti6Al4V alloy using a moving heat source. Then the developed model was applied for the deposition of ceramic materials Al2O3 and TiC on Ti6Al4V alloy substrate. The outcome of this model is to predict temperature distribution, cooling rate, melt pool depth, heat affected zone and residual stress. This study mainly highlights the thermal effect on the residual stresses for similar and dissimilar clad/substrate materials and suggests the suitable cladding material with minimum residual stress

Process mapping of laser surface modification of AISI 316L stainless steel for biomedical applications

A 1.5-kW CO2 laser in pulsed mode at 3 kHz was used to investigate the effects of varied laser process parameters and resulting morphology of AISI 316L stainless steel. Irradiance and residence time were varied between 7.9 to 23.6 MW/cm2 and 50 to 167 µs respectively. A strong correlation between irradiance, residence time, depth of processing and roughness of processed steel was established. The high depth of altered microstructure and increased roughness were linked to higher levels of both irradiance and residence times. Energy fluence and surface temperature models were used to predict levels of melting occurring on the surface through the analysis of roughness and depth of the region processed. Microstructural images captured by the SEM revealed significant grain structure changes at higher irradiances, but due to increased residence times, limited to the laser in use, the hardness values were not improved

Tolerance and biosorption capacity of Zn²⁺, Pb²⁺, Ni³⁺ and Cu²⁺ by filamentous fungi (Trichoderma harzianum, T. aureoviride and T. virens)

Heavy metal pollution has become a serious environmental issue in the last few decades. There is a need to develop potential technology that can remove toxic heavy metals ions found in polluted environments. This study was undertaken to determine the resistance levels of different concentrations of heavy metals using filamentous fungi of Trichoderma aureoviride, T. harzianum, and T. virens. Based on the results, the T. virens strain T128 gave the highest tolerance ability for Ni³⁺ and Pb²⁺ in a 1200 mg/L concentration. The accumulation and uptake capacity was determined by the maximum removal of Pb²⁺, Cu²⁺, and Ni³⁺ by a T. harzianum in liquid medium when compared to other fungi. The metal removal occurred at a concentration of 500 mg/L and was 13.48 g/g for Pb²⁺, 3.1254 g/g for Cu²⁺ and 0.8351 g/g for Ni³⁺. For Zn²⁺, the highest tolerance and uptake capacity of metal was recorded at 3.1789 g/g by T. virens

Thermal fatigue properties of laser treated steels

This paper presents the thermal fatigue resistance of laser treated steels. The C40 and AISI H13 steels were machined into a geometry which allowed thermal gradients on the inner and outer surface during testing. A CO2 laser system was used with a focused spot size of 0.09 mm on the sample surface. The laser peak power and pulse repetition frequency (PRF) range were set to 760 and 1515 W, and 2900 to 3500 Hz respectively. The thermal fatigue machine used consists of Nabertherm model cylindrical high temperature furnace with digital control panel, controlled temperature quenching system, and pneumatics control sample movement mechanism. The thermal fatigue test involved immersion of samples into molten aluminium, and quenched in ionised water emulsion at 17°C temperature. The quenching system equipped with thermocouple to control the water temperature. Testing was done at a total of 1,750 number of cycles. Internal surface cooling was controlled by water inlet and outlet tubes. Samples were cleaned using NaOH solution after thermal fatigue testing to remove oxides on the surface. The solution temperature and magnetic stirrer speed were set to 100°C and 4.5 rpm respectively. Samples were characterised using scanning electron microscope (SEM), energy discharge x-ray spectroscopy (EDXS) and 2D stylus profilometer. Presence of different phases on the sample surface were analysed from back-scattered detector micrographs. Heat checks were observed on laser glazed surface at several regions. Carbides and oxides elements were detected on the sample surface after the thermal fatigue test. The relationship between surface roughness of laser treated surface and thermal fatigue behaviour was investigated