激光熔覆技术作为一种先进的修复技术凭借其高速的熔覆效率在修复领域发挥着举足轻重的作用，但是存在材料利用率低与激光能量损耗严重等问题，激光-电复合丝材熔覆技术作为一种新兴的复合熔覆技术具有材料利用率高，激光能量损耗小等特点，但是，该技术的工艺特点目前尚不明确。本文采用激光-电复合熔覆技术对大型回转体零件进行修复，展开预先工艺研究，本文的研究有助于该技术的推广与应用，对降低修复成本实现大型零件的绿色修复有重要意义。

首先，在氮气气体保护环境下，使用激光-电复合丝材熔覆技术在45#钢基体表面进行多道单层630不锈钢丝材熔覆，对熔覆层表面形貌、缺陷分布、微观组织以及元素分布等进行研究，结果表明：熔覆层表面杂质小颗粒随着激光功率的提升而增加，熔覆层表面均未出现缺陷与裂纹，熔覆层组织主要为等轴晶与柱状晶，在熔覆层顶部为等轴树枝晶，组织较为混乱，各部分元素分布均匀。

其次，对不同工艺参数下熔覆层的性能进行研究，分别对不同激光功率、熔覆速度、进给距离下熔覆层的显微硬度和摩擦磨损性能进行了研究，分析了显微硬度、摩擦系数、磨损量、微观磨损形貌随工艺参数的变化规律，结果表明：在当前实验条件下，激光功率为3000W时，熔覆层硬度与耐磨损性能最好；在当前实验条件下，熔覆速度为50mm/s与进给距离为1.2mm时，熔覆层的耐磨损性能最好；与激光功率相比，熔覆速度与进给距离对硬度的影响较小。

最后，制备了测试结合强度的多道多层熔覆试样，采用特制工装进行实验，获得了断裂最大载荷，并对断口形貌、断裂原因进行分析。通过断裂位置、断口形貌及断裂最大载荷评价其结合强度，结果表明：熔覆层与基体之间断裂最大载荷在60KN上下浮动，熔覆层与基体均能良好的结合。

As an advanced maintenance technology, laser cladding technology plays an important role in the maintenance field with its high cladding efficiency, but it still exists some problems like low material utilization and serious energy loss. As a new technology, laser and electricity composited wire cladding technology has the characteristics of high material utilization and low energy loss. However, the process characteristics of this technology are not clear at present. In this paper, the large rotating parts are taken as the research object, which are repaired by laser and electricity composited cladding technology, through which the process is studied beforehead. This research is benefited to the popularization and application of this technology and has great significance on reducing the maintenance cost and achieving the green maintenance of large parts.

Firstly, under the protection of nitrogen atmosphere, multi-channel and single-layer 630 stainless steel wire is cladded on the surface of 45# steel substrate by using laser and electricity composited wire cladding technology. The surface morphology, defect distribution, microstructure and element distribution of the cladding layer are studied. The results show that small impurity particles on the surface of the cladding layer were raised with the increase of laser power, there are not any defects on the cladding surface, The microstructure of the cladding layer is mainly made up by equiaxed crystal and columnar crystal. There is equiaxed dendritic crystal at the top of the cladding layer, where the structure is chaotic but the elements in each part are evenly distributed.

Secondly, the properties of the cladding layer under different process parameters are studied. The microhardness and friction and wear properties of the cladding layer under different laser power, cladding speed and feed distance are studied respectively. The variation laws of microhardness, friction coefficient, wear amount and micro wear morphology with changed process parameters are analyzed. The results show that: Under the current experimental conditions, the hardness and wear resistance of the cladding layer are the best when the laser power is 3000W. Under the current experimental conditions, the wear resistance of the cladding layer is the best, when the cladding speed is 50mm/s and the feed distance is 1.2mm. Compared with the laser power, cladding speed and feed distance have less influence on hardness.

Finally, the multi-channel and multi-layer cladding samples for testing the bonding strength were prepared. The experiments were carried out with the special tooling, the maximum fracture force was obtained, the fracture morphology and fracture cause were analyzed. The bonding strength is evaluated through the maximum fracture force, the fracture morphology, and the fracture location. The results show that the maximum fracture load fluctuates up and down at 60KN, and the cladding layer and the matrix are well bonded.

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