Speaker
Description
Nickel-aluminum bronze (CuBz) alloys are widely used due to their excellent mechanical properties and corrosion resistance. To enhance their use in high-value applications and lower the part replacement costs, improving their surface wear resistance is essential. Metal matrix composite (MMC) coatings have shown promise in this regard. One approach involves laser melting injection (LMI) of spherical fused tungsten carbide (sFTC), containing WC and W2C, onto CuBz substrates, reducing wear by up to 80%. However, residual stresses develop in MMC coatings, causing geometric distortion, reduced fatigue strength, and shorter service life. This study uses neutron diffraction to analyze residual stress profiles in sFTC/CuAl10Ni5Fe4 coatings produced via LMI. A thermo-mechanical finite element model predicts temperature and stress patterns in the re-melted CuAl10Ni5Fe4 bronze. The effects of single/multiple laser tracks and pre-heating on residual stresses were explored. Additionally, detailed microscopic thermal misfit residual stresses were calculated. The results provide insights for optimizing the manufacturing process, reducing residual stresses, and improving MMC coating performance and longevity.
