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Control of the Molten Pool Morphology and Crystal Growth Behavior in Laser Powder Deposition of Single-Crystal Superalloy via Adjusting the Defocusing Amount and Scanning Speed

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Abstract

Stably controlling the monocrystalline nature in the repaired zone is a longstanding challenge for the laser additively repair of single-crystal components. In this study, the coupling effect of laser defocusing amount and scanning speed on the molten pool morphology and associated crystal growth behaviors in laser powder deposition of single-crystal superalloy was studied through single-track experiments and an improved mathematical model. Multi-layer experiments were conducted to verify the practicability of optimized processing parameters. The results indicated that the defocusing amount can effectively adjust the laser energy intensity distribution through changing the laser-powder interaction distance and resultantly tailor the molten pool morphology and associated crystal growth behaviors. With the defocusing amount changing from − 3 to + 3 mm, the toe angle of molten pool increases dramatically and induces the formation of nonideal columnar crystals at the toe edge. The increase in laser scanning speed shrinks the molten pool size, restrains the formation of stray grains and nonideal columnar crystals, and enhances the total-remelting ability of stray grains. Coupling tailoring negative defocusing amount and proper scanning speed (− 3 mm and 9 mm/s are optimal under the given conditions) benefits the epitaxial-growth continuity of columnar dendrites and reproduces complete monocrystalline structure in laser SX-repair process.

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Acknowledgments

This work was supported by the National Natural Science Foundation of China (Grant Nos. 51905253, 51975136, 51575116), the Natural Science Foundation of Guangdong Province of China (Grant No. 2018A030310132), and the Natural Science Foundation of Shenzhen of China (Grant No. JCYJ20190809152401680).

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Authors and Affiliations

  1. School of Mechanical and Electrical Engineering, Guangzhou University, Guangzhou, 510006, China

    Zhaoyang Liu, Zhongwei Liang, Tao Zou & Xiaochu Liu

  2. The Guangzhou Key Laboratory for Strengthen Grinding and High-Performance Machining of Metal Material, Guangzhou University, Guangzhou, 510006, China

    Zhaoyang Liu, Zhongwei Liang & Xiaochu Liu

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Liu, Z., Liang, Z., Zou, T. et al. Control of the Molten Pool Morphology and Crystal Growth Behavior in Laser Powder Deposition of Single-Crystal Superalloy via Adjusting the Defocusing Amount and Scanning Speed. J Therm Spray Tech 31, 2594–2608 (2022). https://doi.org/10.1007/s11666-022-01446-5

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