Ultrasonic assisted vibration platform

1. Technical Overview

definition：
Ultrasonic two-dimensional vibration laser cladding is a composite additive manufacturing technology that combines laser cladding（Laser Cladding）Ultrasonic vibration（Ultrasonic Vibration）The advantage. By introducing two-dimensional vibrations (such asXYThe direction can further improve the microstructure, residual stress distribution, and surface quality of the cladding layer.

core components：

·Laser cladding systemHigh power laser (such as fiber laser), powder feeding system (powder or wire), motion control platform.

·Ultrasonic vibration deviceUltrasonic generator, transducer, amplitude rod, two-dimensional vibration worktable (or vibration head).

·control systemSynchronize control of laser parameters and vibration frequency/Amplitude and motion path.

2. Technical Principle

·laser claddingLaser beam melts the surface of the substrate to form a molten pool, while conveying metal powder to form a metallurgical bonding coating.

·Ultrasonic effect：

ocavitation effectUltrasonic waves generate micro bubbles in the molten pool, which release energy upon rupture and refine the grain size.

oAcoustic flow effectPromote convection in the melt pool, homogenize component distribution, and reduce porosity/Mixed up.

oVibration assistanceTwo dimensional vibration can break the direction of dendritic growth, further refine the structure, and reduce residual stress.

3. Technical Features

advantage：

·Improving microstructureThe grain size is significantly reduced (up to the nanometer level), improving hardness and wear resistance.

·Reduce defects: Reduce porosity (can reduce)30%~50%）Crack sensitivity.

·Residual stress controlThe plastic deformation introduced by vibration can counteract thermal stress and improve fatigue life.

·coating uniformityTwo dimensional vibration makes the thickness of the cladding layer more consistent and the surface roughness（Ra）Can be reduced20%~40%.

challenge：

·Complex process parameters (requiring optimization of laser power, scanning speed, vibration frequency)/Amplitude, etc.).

·The integration design of ultrasonic devices and laser heads is difficult.

·The cost is higher than traditional laser cladding.

4. Key process parameters

·laser parameters: Power（500~3000W）Spot diameter（0.5~3mm）Scanning speed（5~20mm/s）.

·Vibration parameters：

oFrequency:20~40kHz(Ultrasonic range) or low-frequency vibration（<1kHz）.

oAmplitude:5~50μm(Two dimensional vibration needs to match directionality).

·Material selectionNickel based alloys (such asInconel 625）Cobalt based alloys, stainless steel, titanium alloys, etc.

5. Application field

·aerospaceWear resistant coating and high-temperature alloy repair for turbine blades.

·energy equipmentStrengthening the sealing surface of nuclear power valves and repairing gas turbine blades.

·automobile manufacturingRemanufacturing of engine components.

·medical deviceFunctionalized coating on the surface of titanium alloy implants.

6. Research Progress

·2020Literature reports after the year：

oChinese scholars have discovered that two-dimensional vibrations canTi6Al4VThe grain size of the cladding layer varies from50μmdrop to10μmThe following（《Journal of Materials Processing Technology》）.

oThe German team uses ultrasonic vibration to316LImprovement of fatigue life of stainless steel coating200%（《Additive Manufacturing》）.

·Future Direction：

oMulti physics field coupling simulation (laser)-ultrasound-Thermal coupling).

oIntelligent parameter regulation（AIReal time optimization of vibration and laser parameters.

7. References

1. Zhang et al. (2021). 'Effect of ultrasonic vibration on microstructure and properties of laser cladded Inconel 718'.Materials & Design.

2. Wang et al. (2022). '2D vibration-assisted laser cladding: A novel approach for residual stress reduction'.Journal of Manufacturing Processes。