Laser Surface Treatment Processes

Laser Surface Treatment
Processes
“Beauty is only skin deep, but it is only the

skin you see”
PATIL S B
Assistant Professor-Mechanical Engineering
College of Engineering, Pune-411 005
shri.sb@gmail.com
Short term Refresher course On “ Modern Trends in Machining and Materials” at VJTI, MUMBAI
Why surface treatment?
 Service life
Oxidation resistance
Corrosion resistance
Wear resistance
Hardness
Tribological properties
High temperature hardness
Strength
Erosion resistance
Fatigue life
11/28/09 Laser Surface Treatment Processes 2

Common advantages of laser surface treatment
processes
 Chemical cleanliness
 Controlled thermal penetration and therefore distortion
 Controlled thermal profile and therefore shape and location of heat

affected region
 Less after machining, if any, is required
 Remote non contact processing is usually possible
 Relatively easy to automate

Laser surface treatment processes
 Laser transformation hardening
 Laser surface melting
 Laser surface alloying
 Laser cladding
 Particle injection
 Laser surface texturing
 Laser stripping
 AND MANY--- MANY MORE!

Regions of laser power density and pulse duration
108 Shock
hardening
1 102 104 106
10-2 Energy density
106 Drilling (J/mm2)
Welding
Glazin
g
104 Cutting
Power Cladd
ing
density
(W/mm2) 102 C
Trans
fo rmati
on
harde
n ing
1
10-2
10-8 10-6 10-4 10-2 1 102
Interaction time (Sec.)

Laser transformation hardening
-Selective hardening for wear resistance
- Also to change metallurgical and mechanical properties
Practical uses of laser treatment

1. Increase in hardness
2. Increase in strength
3. Reduced friction
4. Improved wear resistance
5. Increase in fatigue life
6. Creation of surface carbide
7. Creation of unique geometrical wear pattern
8. Tempering

Laser hardening features

Principle of laser transformation hardening
Conventional hardening Laser transformation

Heating to a temperature above hardening
α -γ transformation (750°to 3
Heating rapidly (10 K/sec)
900°C) depending on the
to a temperature between
carbon content where the soft
pearlite phase transforms to
a critical solid-state
austenite and carbon particle transformation temp. and
dissolves. melting temp.
Upon subsequent cooling, the The large volume of
austenite transforms to adjacent material acts as
martensite. an efficient sink, which
3
cools (10 K/sec) the
surface rapidly.

Principle of laser hardening-0.35%C
1600 Liquid
Liquid
+
Beam Austenite
1200 1130
Martensite Austenite
Austenite
800 +
Cementite
723
Base
material
400 Ferrite + Cementite
Fe 0.35 Wt % C

TTT Diagram

TTT Diagram for 0.8%C steel
°C
800 Austenite
700
600
Coarse Pearlite
R. C. 5-20
Fine Pearlite R. C. 30-40
500
Feathery Bainite R. C. 40-50
400
Acicular Bainite
300 R. C. 50-60
MS
200
100
Martensite
R. C. 65-70 Mf
1 2 4 8 15 30 1 2 4 8 15 30 1 2 4 8 15
Hours
Seconds Minutes

Principal process variables of laser hardening
1. Material properties
- Composition
- Geometry
- Absorptivity
2. Beam properties
- Wavelength
- Power
- Power density
- Beam interaction time
3. Process properties
- Process gas
- Coverage of large areas

Scheme of specimen preparation

100 % MIRROR FOR
BEAM DEFLECTION Nd: YAG PULSED
LASER
3-AXIS GANTRY TYPE

MACHINE TOOL
SYSTEM
X
Y
Fig. 4.2 The schematic set-up showing Nd: YAG laser system
with 3-axis gantry

Thermal modeling
The general governing equation of heat conduction of transient behavior in

cylindrical co-ordinate is given as
1 ∂  ∂T  1 ∂  ∂T  ∂  ∂T  ∂T
 k r  + 2  k  +  k  + q = ρ .c p
r ∂r  ∂r  r ∂θ  ∂θ  ∂z  ∂z  ∂t
As per the assumption neglecting the effect of internal heat generation on the
temperature distribution the equation for axis-symmetric heat conduction
reduces to
∂ 2T 1 ∂ T ∂ 2T 1 ∂ T
+ + 2 =
∂r 2
r ∂ r ∂z α ∂t
Where
k
α= is thermal diffusivity
ρ.c p

*From equation (3.16)
 r2 
− 
T ( r , z, t ) = Tm axe
 4α t 
 
Q f  4α t  −4αz t − ( z4α+ta ) 
 2 
2 2 2
 z2 + a2   z   −  4rα t 
T ( r , z, t ) = z e − e  + z + a erfc
2 2  − ( z ) erfc
   e   ---(3.26)
k  π     2 αt   2 α t  
   
The above equation can be used to calculate temperature at any
point and can be further reduced by using repeated integrals of
error function to
 r2 
2Q f αt   z   z2 + a2  − 4αt 
T (r , z , t ) = ierfc  − ierfc '  e  
k   2 αt   2 αt



---(3.27)
Equation (3.27) is the final equation to calculate the temperature at

the desired location.

%C % Si % Mn %S %P With graphite Flakes in
*Material composition a pearlitic matrix
3.35 2.48 0.84 0.068 0.068
Material microstructure
Pearlite
Graphite flakes

Metallographic analysis
Retained austenite and
undissolved graphite
Coarse martensite

Confirmation experiment

Microstructures for various degrees of overlaps-1
0% Degree of overlap



Microhardness distribution along surface for various degrees of overlaps-1
Hardness Distribution for 0% overlap Hardness distribution for 10% overlap
800
800
Microhardness (Hv)
700
Hardness (Hv)
600 600
500
400 400
300
200 200
100
0 0
1050
1250
1650
2050
2250
2450
2650
1450
1850
250
450
650
850
50
50
50
50
50
50
50
50
0
50
50
50
25
45
65
85
10
12
14
22
24
26
16
18
20
Distance (Microns) Distance (Microns)
Hardness distribution for 20% overlap
800
700
Hadrness (Hv)
600
500
400
300
200
100
0
50
0
0
0
50
50
50
50
50
50
50
50
50
25
45
65
85
10
12
14
16
18
20
22
24
26 Distance (Microns)

Microhardness distribution along surface for various degrees of overlaps-2
Hardness distribution for 30% overlap Hardness distribution at 40% overlap
800 1000
700
Hardness (Hv)
Hardness (Hv)
600
800
500 600
400
300 400
200 200
100
0 0
50
50
50
50
50
50
50
50
50
0
0
50
50
50
50
50
50
50
50
50
50
50
0
0
0
85
25
45
65
25
45
65
85
26
10
12
14
16
18
20
22
24
22
10
12
14
16
18
20
24
26
Distance (Microns) Distance (Microns)
Hardness distribution at 50% overlap
700
600
Hardness (Hv)
500
400
300
200
100
0
0
0
50
50
0
50
50
50
50
50
50
50
50
25
85
45
65
12
10
14
16
18
20
22
24
26
Distance (Microns)

Comparison of theoretical & actual case depth
Theoratical case
Com parision of theoratical & experim ental case depth depth
Experimental case
depth
600
500
Case depth (microns)
400
300
200
100
0
890 890 890 905 905 905 918 918 918
Beam pow er (w atts)

Conclusion-1
 Microstructure analysis reveals that laser hardening of Cast Iron using

Nd: YAG laser is quite feasible.
 The transformation of austenite to martensite during rapid cooling cycle

is diffusion less and depends on the cooling (quenching) rate.
 No abnormal metallurgical change is witnessed during the process.
 The process parameters like laser power density, spot size, beam
energy distribution as well as the thermo physical properties of the
material affect the process, independently.

Conclusion-2
 The increase in surface hardness is common in the range of 600 to

700 Hv from 240 Hv.
 During overlapping of spots tempering effect is observed. For 50%

overlap using optimum parameters typically ranges in between 500 to
550 Hv, however it is much more consistent and uniform.
 The experimental results fairly match with the theoretical.
 The wear characteristic of Cast Iron is improved during laser

hardening.

Laser surface melting
 Similar experimental arrangement as transformation hardening, except
a focused or near focused beam is used
 Characteristics
-Moderate to rapid solidification rates producing fine near homogenous

structures.
-Little thermal penetration, resulting less distortion.
-Surface finishes of around 25 µm are fairly easily obtained, reduces

need of post processing.
-Process flexibility

Common material for laser melting-1
 Cast iron
Inhomogeneous structure of ferrite and graphite (flakes, sphere etc)
changes to graphite to cementite and austenite to martensite
Carbon dissolution- Increased hardness
- increased wear resistance
 Stainless steel
Production of fine austenitic and martensitic structures
Improved corrosion resistance

Common material for laser melting-2
 Tool and special steels
Hardening through solution treatment –Carbide dissolution
- Controlled quench rates for fine dispersion of carbides
Fine carbide dispersion with high hot hardness
 Tendency to crack at higher hardness

Preheat requirement
-500° C-Low carbon steel

-650° C-0.7 wt% C steel
-700° C-Tool steel

Laser surface alloying
 Similar to laser melting except another material is injected into melt
pool
 Characteristics
-Fine and homogenous microstructure
-Minimal segregation
-Some surface alloys requires rapid quench rates e.g. Fe-Cr-C-Mn
-Varied surface thickness-1 to 2000µm
-Loss of more volatile components can be expected

Laser alloying/cladding principle

Laser surface alloying-Applications
Material Alloying element
Titanium Alloying with carbon or nitrogen

Production of hard carbide or nitrides
Cast iron Alloying with Cr, Si or C
Cheap C. I. into exotic irons
Steel Alloying with Cr
Improves corrosion resistance
Aluminium Surface hardening by alloying with Si, C, N & Ni
Superalloys Alloying with Cr

Laser alloying advantages
 Permits precise selection of area to be modified
 Requires a very small amount of modifier alloy
 Results in extremely rapid heating and cooling of the surface
 Produces wide variety of chemical and microstructural states outside of typical phase
diagrams
 Produces no distinct bond-line; will not delaminate
 Requires little or no surface preparation for certain applications
 Produces minimal hazardous waste
 Performed remotely with robotics and fiber-optics
 Performed at rates between 20-50 sq. ft./h

Laser alloying of D2 steel-1

Laser alloying of D2 steel-2

Laser alloying-applications
Aluminum engine block

Copper/stainless steel cryogenic valves
4340 Steel moulds

Titanium impeller wear

Alloying of Al cylinder liner with
Si

Alloying of Al cylinder liner with
Si

Laser alloying-General applications
 Corrosion Protection
 Superior alloy, refined grain size
 Pumps, cylinders, rollers and die-casting dies
 Wear Resistance
 Surface metal matrix composites using SiC, WC, TiC, TiB2, Al2O3, etc.
 Surface modification of dissimilar materials
 Durable non-skid Surfaces
 Protection from hydrogen embrittlement

Laser cladding
 To overlay one metal with another to form a sound
interfacial bond or weld without diluting metal with
substrate material.
 Methods
-Laser cladding with pre placed powder

-Blown powder laser cladding

Laser cladding
Advantages
 Can produce denser coatings with little or no porosity, finer surface finishes,
more consistent layer thicknesses, and more precise clad placement, than
traditional thermal spray techniques.
 Is inherently a low heat input process, resulting in low dilution, fine

microstructures, small heat affected zones (HAZ), and low distortion.
 Helps reduce processing time.
 In specific applications, laser cladding may restore parts to their original

dimensions without secondary operations.
 Improves upon the materials inherent susceptibility to corrosion, wear and

oxidation.

Laser cladding- Industries and Applications
 Aerospace
 Automotive
 Marine
 Oil and gas industries
 Power generation
 Restoration of bits, dies, industrial blades, and motor casings
 Remanufacture of engine components
 Hard facing

Laser cladding- Common clad materials
 Carbon Steels
 Carbide Composites
 Cobalt-base Superalloys
 Stainless Steels
 Titanium Alloys
 Nickel-base Superalloys

Cladding typical data

Cladding with fiber coupled laser



Cladding with diode laser

Cladding with diode laser


Particle injection
 Similar to cladding process by blown powder except that
the particles projected into molten pool do not melt entirely
- Improved hardness and wear resistance due to reduced

friction
- Hardening of Al & its alloys with TiC, SiC, WC or Al2O3

particles

Laser surface texturing
 A chopped laser beam is
used to make a regular
patterns or small pits or
dimples

LST Concept
 This technology is based on a pulsating laser beam that, by

a material ablation process, generates thousands of micro
pores or dimples in one of the mating surfaces. All
parameters are highly controlled and can be optimised for
each application if required.
 Typically the density of micro-pores is 50% of the surface

area

LST Advantages
 Reduces metal to metal contact

 Could facilitate speed / performance increase
 Reduces friction by up 75%
 Wear resistance can be increased 6 fold in extreme cases
 Improves component life & reliability
 Longer life in lubricant starvation situations
 Improves seizures resistance 2 fold
 Reduces power consumption
 Allows increased service periods or down sizing
 Reduces maintenance costs
 Heat generation can be reduced by 30%

LST-Applications

LST-Other possible applications
 Mechanical seals
 Duo-cone Seals
 Roller bearing thrust ribs
 Thrust Bearings
 Thrust collars/washers
 Water pump seals
 Plain & hydrodynamic bearings
 Piston rings & other engine components
 Surfaces lubricated by water or non flammable solutions
 High temperature surfaces lubricated by ATF or other low viscosity
lubricants
 Gas Seals in turbines
 Helps reduce fretting corrosion

LST applications in Seal failure
LST can help prevent or minimise the most common causes of
mechanical seal failure
 Wear due to frequent start-ups

 Fluctuations in process pressure
 Abrasive media
 Fluid vaporizes or exceeds flash point
 Fluid attacks / corrodes / degrades seal components
 Cavitations breaks up faces
 Mixed lubrication
 Debris builds up around seal
 Media crystallisation
 Dry running

Laser stripping
• Paint
• Scale
LASER STRIPPING PORCESS:
The laser is programmed to maximize absorption of the laser beam by the
contaminated (paint, scale) material. This typically results in the substrate
material (metal, plastic, ceramic), reflect most of the laser energy leaving a
clean stripped surface. Due to their high reflection factor, metallic surfaces are
especially suitable for laser cleaning.

Laser stripping process

Advantages of Laser Stripping
 Improved Quality
 Less labour intensive
 Improved throughput
 No secondary waste
 Lower health risk
 Low noise and dust
 Easy to automate
 Lower consumable and disposal costs
 PVDF coating removal Application

Fe-Fe3C Phase Diagram


Laser Surface Treatment Processes

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Laser Surface Treatment Processes

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Laser Surface Treatment

“Beauty is only skin deep, but it is only the

11/28/09 Laser Surface Treatment Processes 2

 Controlled thermal penetration and therefore distortion

 Controlled thermal profile and therefore shape and location of heat

 Less after machining, if any, is required

 Remote non contact processing is usually possible

 Relatively easy to automate

11/28/09 Laser Surface Treatment Processes 3

 Laser surface melting

 Laser surface alloying

 Laser surface texturing

 AND MANY--- MANY MORE!

11/28/09 Laser Surface Treatment Processes 4

Interaction time (Sec.)

11/28/09 Laser Surface Treatment Processes 5

Practical uses of laser treatment

11/28/09 Laser Surface Treatment Processes 6

11/28/09 Laser Surface Treatment Processes 7

Conventional hardening Laser transformation

11/28/09 Laser Surface Treatment Processes 8

11/28/09 Laser Surface Treatment Processes 9

11/28/09 Laser Surface Treatment Processes 10

11/28/09 Laser Surface Treatment Processes 11

11/28/09 Laser Surface Treatment Processes 12

11/28/09 Laser Surface Treatment Processes 13

3-AXIS GANTRY TYPE

11/28/09 Laser Surface Treatment Processes 14

The general governing equation of heat conduction of transient behavior in

11/28/09 Laser Surface Treatment Processes 15

Equation (3.27) is the final equation to calculate the temperature at

11/28/09 Laser Surface Treatment Processes 16

11/28/09 Laser Surface Treatment Processes 17

11/28/09 Laser Surface Treatment Processes 18

11/28/09 Laser Surface Treatment Processes 19

10% Degree of overlap

11/28/09 Laser Surface Treatment Processes 20

30% Degree of overlap

11/28/09 Laser Surface Treatment Processes 21

40% Degree of overlap

50% Degree of overlap

11/28/09 Laser Surface Treatment Processes 22

Hardness Distribution for 0% overlap Hardness distribution for 10% overlap

Distance (Microns) Distance (Microns)

Hardness distribution for 20% overlap

11/28/09 Laser Surface Treatment Processes 23

Hardness distribution for 30% overlap Hardness distribution at 40% overlap

Hardness distribution at 50% overlap

11/28/09 Laser Surface Treatment Processes 24

11/28/09 Laser Surface Treatment Processes 25

 Microstructure analysis reveals that laser hardening of Cast Iron using

 The transformation of austenite to martensite during rapid cooling cycle

 No abnormal metallurgical change is witnessed during the process.

11/28/09 Laser Surface Treatment Processes 26

 The increase in surface hardness is common in the range of 600 to

 During overlapping of spots tempering effect is observed. For 50%

 The experimental results fairly match with the theoretical.

 The wear characteristic of Cast Iron is improved during laser

11/28/09 Laser Surface Treatment Processes 27

-Moderate to rapid solidification rates producing fine near homogenous

-Little thermal penetration, resulting less distortion.

-Surface finishes of around 25 µm are fairly easily obtained, reduces

11/28/09 Laser Surface Treatment Processes 28