Session: Research Posters

Paper Number: 120106

120106 - Design for Manufacturing of Cemented Carbide Coated Components Toward High Wear and Impact Resistance Performance 

Wear- yet impact-resistant demand under heavy-load service condition is a high performance challenge for coated components design and processing. Integrated optimization of design and processing is a right way for achieving the high performance but leading to the highly ill-posed multi-objective optimization problem of manufacturing hard to be solved as a result of the multi-source constraints from geometry, materials, and structure design parameters under the processing.

To solve such a high-performance manufacturing problem, a high-performance manufacturing (HPM) principle is proposed on the material-product-process correlation via the pivot role of surface integrity that determines the desired final performance of components. Under the HPM framework, a new strategy of design for manufacturing (DFM) with integrated design and processing is developed and demonstrated for a component comprising of thermally sprayed cemented carbides coated flat block/bulk cylinder mates for potential application in hydraulic machinery. In the DFM, the processing effect of thermal spray on the performance of coated components is incorporated by a process signature (PS) correlative analysis on thermodynamics to post the design parameters of high sensitivity to the major surface integrity that determines final wear and impact performance of the coated component.

Specifically, an impact performance model of DFM is constructed for the component with wear-resistant a WC-12Ni/Ni60A two-layer thermal spray coating on 17-4PH martensitic steel substrate, and the Ni60A interlayer thickness is demonstrated as a geometry design parameter for the integrated optimization with the two-layer coated component material and structure. As verified with experimental test, the impact crater depth, surface hardening and residual stresses under the impact load are identified as major surface integrity parameters determining the wear/impact performance. The design parameters of geometry, material and structure are quantitatively correlated to the final performance by the PS correlative analysis on the identified surface integrity to internal material loading of plastic/elastic strain energies in the coating-substrate system. The characteristic PS sensitivity analysis reveals coating thickness a high-sensitivity parameter for design, facilitating a buffering effect of reduced peak stresses among the coating-substrate system under impact loads.

The DFM optimization is understood by irreversible thermodynamics as reducing energy dissipation of the internal material loading from the external impact loads. The manufacturing inverse problem is thus solved by material-oriented regularization (MOR) on the PS correlations integrating the design and processing phases. The manufactured component, with optimal Ni60A interlayer thickness of 75-100 μm at a top WC-12Ni coating of 200 μm, achieves a desired performance up to 6000 impacts under a nominal load of 15 kN.

Presenting Author: x.p. Zhu Dalian University of Technology

Presenting Author Biography: Professor, Dr. X.P. Zhu
Surface Engineering Laboratory, School of Materials Science and Engineering, Dalian University of Technology, China
(1) Current research
Manufacturing process development involving surface and coating technologies and engineered surface/interface evaluation.
(2) Work Experience
2014/3 - present, Deputy director, Key Laboratory of Materials Modification by Laser, Ion, and Electron Beams, Ministry of Education, China
2011/12 - present, Professor, School of Materials Science and Engineering, Dalian University of Technology, China
2003/7 – 2006/3, COE postdoc, Extreme Energy-Density Research Institute, Nagaoka University of Technology, Japan
(3) Academic Position
Member of Standing Committee, Surface Engineering Brach of Chinese Mechanical Engineering Society, 2018-2022, 2023-2027

Authors:

M.K. Lei Dalian University of Technology
x.p. Zhu Dalian University of Technology
s.j. Zhang Dalian University of Technology