Design and Effect of Resonant Ultrasonic Vibration-Assisted Laser Cladding (R-UVALC) on AlCrFeMnNi High-Entropy Alloy

Area of Science:

• Materials Science
• Metallurgy
• Surface Engineering

Background:

• Laser cladding is a crucial surface modification technique.
• High-entropy alloys (HEAs) offer superior material properties.
• Improving the quality and performance of laser-clad HEA coatings is essential.

Purpose of the Study:

• To investigate the effects of resonant ultrasonic vibration-assisted laser cladding (R-UVALC) on AlCrFeMnNi high-entropy alloys.
• To optimize ultrasonic vibration parameters for enhanced coating properties.
• To evaluate the microstructural, mechanical, and tribological improvements.

Main Methods:

• Finite element analysis (FEA) for R-UVALC setup simulation.
• Laser cladding of AlCrFeMnNi HEAs with varying ultrasonic vibration amplitudes (0-15 µm) at 20 kHz.
• Microstructural analysis (grain structure, phase identification via XRD/XPS).
• Microhardness testing, friction coefficient measurement, and wear scar analysis.

Main Results:

• Ultrasonic vibrations reduced pores/cracks, increased clad breadth, and improved layer consistency.
• Grain structure transformed from columnar to equiaxed at 5 µm amplitude.
• Phase structure shifted to a single BCC phase with 5 µm amplitude.
• Microhardness tripled, and the lowest friction coefficient was achieved at 5 µm amplitude.
• Wear analysis indicated reduced scar depth and a primary abrasive/oxidative wear mechanism.

Conclusions:

• R-UVALC significantly enhances laser cladding of HEAs.
• An ultrasonic vibration amplitude of 5 µm optimizes coating microhardness and wear resistance.
• The R-UVALC process shows great potential for improving surface engineering applications.