高速钢激光沉积过程光-粉交互作用与固态相变研究

通过激光沉积技术对履带车辆主动轮齿圈进行表面改性，可以大幅提升其表面综合力学性能。精确的能量与质量控制是决定激光沉积构件质量和性能的关键，然而系统输入与能量/质量利用率间具有复杂的非线性关系，相关数值模型在能量和质量输入的确定上缺乏可靠的正向计算依据。能量和质量输入作用下的沉积固态相变历史是影响激光沉积构件质量与形变的重要因素之一，受限于原位测量实验条件的限制，目前仍然缺乏研究沉积过程相变的有效手段。

本文以T15高速钢异质材料激光沉积为研究对象，首先通过相变动力学试验建立了沉积材料冷却过程的扩散型相变及马氏体相变的动力学模型。在此基础上，通过Gleeble热模拟试验获得了不同温度下材料的单相本构。结果显示奥氏体态的T15高速钢在受力过程会产生连续动态再结晶而导致应变软化。温度对贝氏体T15高速钢的屈服强度影响最大，当温度从400 ℃降低到200 ℃时屈服强度σ_0.15提高了48.1%。

基于同轴送粉激光沉积的粉末-激光-熔池交互作用机理，提出了一个综合的激光吸收率（η）与质量利用率（e）的正向计算模型。详细描述了激光沉积的三个主要物理过程：粉末对能量的遮挡及其升温、基体能量吸收与熔池形成、粉末捕获与沉积道次形成。模型通过入射角的二次修正，解决了质量-能量耦合对计算的影响。与实验结果对比发现，入射角是影响能量利用率的关键因素，当模型将其考虑为受系统输入影响的变量时，模型精度从88.5%提高到了92.7%。当沉积层和基体为不同材料时，材料的熔点差异会导致熔池宽度变化和边界偏移，考虑异质材料熔点差异可以将计算误差从7.8%降至3.2%。

在系统能量和质量输入确定的基础上，本文提出了一种通过比较-迭代模拟与实测变形曲线来识别相变物理特征的方法。设计了激光沉积 过程变形的DIC原位测量实验，通过变形曲线对比与微观组织表征，论证了碳化物（MC、M6C等）析出使得参与体积型相变的碳含量比名义碳含量低了0.35%，由此导致马氏体相变温度提高了208 ℃。参与相变的碳含量降低导致马氏体相变产生的压应力提高，马氏体相变迁移 率降低了约73%。进一步考虑了表面氧化与自发回火的影响。基于上述分析，建立了全面的T15高速钢沉积热-力-相变耦合模型。

最后，本文应用上述研究成果，对主动轮齿圈试件进行了激光沉积强化，并通过专用台架试验模拟实际服役工况，对 齿圈抗冲击磨损性能进行了评价。台架试验结果显示，相比中频感应淬火工艺，在预张紧力为2 t的19小时台架试验中齿面平均磨损量从0.32 mm降至0.17 mm，磨损量降低了46.9%。且在长时试车后表面无裂纹缺陷，强化层的抗冲击稳定性满足车辆服役技术要求。

Surface modification of a track vehicle drive gearwheel using laser deposition technology can significantly improve the comprehensive mechanical properties of the surface. Precise control of energy and mass is critical to the quality and performance of laser-deposited components. However, there is a complex nonlinear relationship between system input and energy/mass utilization efficiency. Relevant numerical models lack a reliable predictive basis for determining energy and mass input. The history of solid-state phase transformation under the influence of energy and mass inputs is one of the key factors affecting the quality and deformation of laser-deposited components. Due to limitations imposed by the experimental conditions of in-situ measurements, effective means to study the entire deposition phase transformation process are currently lacking.

This thesis focuses on the dissimilar material laser deposition of T15 high-speed steel. First, a diffusion-type phase transformation model and a martensitic phase transformation kinetic model for the cooling process of the deposited material were established through phase transformation kinetic tests. On this basis, the monophase constitutive behavior of the material at different temperatures was obtained through Gleeble thermal simulation tests. The results show that the austenitic state of the T15 high speed steel undergoes continuous dynamic recrystallization during the loading process, resulting in strain softening. Temperature has the greatest effect on the yield strength of bainitic T15 high speed steel, with a 48.1% increase in yield strength (σ_0.15) when the temperature is lowered from 400 °C to 200 °C.

Based on the powder-laser-molten pool interaction mechanism in powder-based laser-directed energy deposition, a comprehensive forward calculation model for laser absorptivity (η) and powder catchment efficiency (e) was proposed. The model elaborates on three main physical processes of laser deposition: powder shielding and heating, substrate energy absorption and molten pool formation, and powder captured and track formation. The model addresses the effect of mass-energy coupling on calculations through secondary corrections based on the incidence angle. A key factor affecting energy utilization efficiency was identified through a comparison with experimental results: the incidence angle. When the model considers the incidence angle as a variable affected by system inputs, the model accuracy increases from 88.5% to 92.7%. In cases where the deposition layer and substrate are made of different materials, the differences in melting points lead to variations in molten pool width and boundary displacement. By accounting for the dissimilar material melting point differences, the calculation error can be reduced from 7.8% to 3.2%.

Based on the identified energy and mass inputs to the deposition system, a methodology was proposed to understand and identify the physics of phase transformations by iteratively comparing the deformation histories of measurements and simulations. An in-situ measurement experiment using Digital Image Correlation technology was designed to capture the deformation during the laser deposition process. By comparing deformation curves and microscopic structure characterization, it was shown that the precipitation of carbides (MC, M6C, etc.) leads to a 0.35% reduction in carbon content participating in volume-type phase transformation compared to the nominal carbon content. As a result, the martensitic phase transformation temperature increased by 208 °C. The reduced carbon content participating in the phase transformation resulted in higher compressive stresses during martensitic transformation and a decrease in martensitic phase transformation mobility by approximately 73%. The effects of surface oxidation and spontaneous tempering were also considered. Based on the above analysis, a comprehensive thermal-mechanical-phase transformation coupling model of T15 high-speed steel deposition was established.

Finally, this thesis applied the above research results to the laser deposition reinforcement of the active gearwheel specimen, and evaluated the anti-impact wear performance of the gearwheel by simulating the actual service conditions through the special bench test. The results from the test rig demonstrated that, compared to the medium-frequency induction hardening process, the average gear surface wear reduced from 0.32 mm to 0.17 mm in a 19-hour test with a pre-tension force of 2 tons, leading to a reduction of 46.9% in wear. Furthermore, no surface crack defects were observed after extended test runs, and the impact resistance stability of the reinforced layer met the technical requirements for vehicle operation.

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