在高端智能制造与再制造技术中，激光熔覆占据着举足轻重的地位，其核心是将金 属粉末在基体表面熔化进而形成性能优异的熔覆层，从而实现零部件性能的提升。然而， 基体与熔覆层之间材料属性不同，因而热物性差异悬殊，致使熔覆层容易出现气孔、裂 纹、微观组织粗大以及应力集中等问题，极大限制了激光熔覆在工程实践中的应用，而 超声辅助可以通过改变温度场和应力场的方式进而改善凝固组织和力学性能。因此，本 文以 Ni60 合金为研究对象，基于理论分析，借助试验与数值模拟相结合的方法展开研 究，深入探讨超声能场引发的空化效应、声流效应以及热效应对激光熔池凝固过程的调 控机制。针对超声振动于熔池传热传质中的作用机理，分析其在性能优化及组织细化方 面的机制。具体研究内容与结论如下:

首先采用 COMSOL Multi-physics 软件中的固体力学、固体传热和压力声学等功能模 块，构建了超声辅助激光熔覆镍基合金过程的温度场以及应力场模型，并对其进行数值 模拟。通过在模型的温度场中选取节点，发现最大温度梯度出现在熔覆层与基体的结合 处，且随着超声振幅的增加温度梯度先减小后增加，凝固速率先增加后减小，同时引入 超声振动后熔池最高温度由 2540 K 降低到 2360 K。在应力场中选取路径，发现在熔覆 层与基体的结合界面处产生了应力集中现象，这成为涂层出现裂纹的首要因素。残余应 力由无超声时的 710 MPa 减小到超声振幅为 24 μm 的 665 MPa，熔覆末端残余应力发生 突变，说明此时材料发生了变形。

其次，开展了不同超声振幅下(0 μm、12 μm、24 μm 和 36 μm)单道熔覆试验，通过 和实验数据的比较，对所建立模型的可靠性进行了验证。借助电子背散射衍射仪(EBSD) 以及扫描电子显微镜(SEM)等分析手段，从熔覆层宏观形貌和微观组织两个方面探讨了 超声波对熔覆涂层的影响机制。最终结果证实，当超声振幅不断上升时，稀释率和润湿 角都呈先减小后增加的趋势，当振幅为 24 μm 时稀释率最低为 25%，润湿角最低为 65°， 超声振幅的施加使熔覆层底部的柱状晶减少且生长方向也发生了改变，超声波对金属熔体的搅拌效应使得柱状枝晶发生破裂，从而造成涂层组织由粗大柱状枝晶变为树状晶、 等轴枝晶。

最后，开展了超声辅助激光熔覆 Ni60 涂层的耐磨耐蚀性能研究，通过分析显微硬 度、耐磨性能、NaCl 和 H₂SO₄ 溶液中的耐蚀性能，探讨超声振幅对熔覆层性能的影响。 结果表明，超声的施加使涂层的平均显微硬度提升了 45.4%，平均摩擦系数降低 42.9， 涂层的磨损率以及磨损痕迹的宽度和深度逐渐减小，磨损机制由无超声时严重的磨粒磨 损、粘着磨损和剥层磨损向轻微的磨粒磨损转变，不同超声振幅下熔覆层在 3.5 wt.% NaCl 溶液中的耐蚀性能优于 3.5 wt.% H₂SO₄ 溶液，超声振幅为 24 μm 时涂层的耐磨耐蚀性能最佳。

In high-end intelligent manufacturing and remanufacturing technology, laser cladding occupies a pivotal position, the core of which is to melt metal powder on the surface of the substrate to form a cladding layer with excellent performance, so as to improve the performance of parts. However, due to the different material properties between the matrix and the cladding layer, the thermal and physical properties of the cladding layer are very different, which makes the cladding layer prone to porosity, cracks, coarse microstructure and stress concentration, which greatly limits the application of laser cladding in engineering practice. In this paper, Ni60 alloy is taken as the research object, based on theoretical analysis and by combining numerical simulation and experiment, the regulation mechanism of cavitation effect, acoustic flow effect and thermal effect induced by ultrasonic energy field on the solidification process of laser melt pool is deeply discussed. Aiming at the main action mechanism of ultrasonic vibration in the heat and mass transfer process of molten pool, the mechanism of its performance optimization and microstructure refinement was analyzed. The specific research contents and conclusions are as follows:

Firstly, a three-dimensional model of temperature field and thermo-stress coupling in the process of Ni-base alloy cladding assisted by ultrasound was established by using the functional modules of solid mechanics, solid heat transfer and pressure acoustics in COMSOL Multiphysics software, and the numerical simulation was carried out. By selecting nodes in the temperature field of the model, it was found that the maximum temperature gradient appeared at the junction of the cladding layer and the matrix, and with the increase of ultrasonic amplitude, the temperature gradient first decreased and then increased, and the solidification rate first increased and then decreased. At the same time, the application of ultrasound reduced the maximum temperature of the molten pool from 2540 K to 2360 K. By selecting a path in the stress field, it is found that stress concentration occurs at the bonding interface between the cladding layer and the matrix, which is the main reason for the crack of the cladding layer. The residual stress decreases from 710 MPa in the absence of ultrasound to 665 MPa in the ultrasonic amplitude of 24 μm, and the residual stress at the end of the cladding layer changes abruptly, indicating that the material is deformed at this time.

Secondly, single-channel cladding tests were carried out at different ultrasonic amplitudes (0 μm, 12 μm, 24 μm and 36μm), and the reliability of the established model was verified by comparing with the experimental data. By means of electron back scattering diffractometer (EBSD) and scanning electron microscope (SEM), the influence mechanism of ultrasonic wave on the cladding coating was investigated from two aspects of macroscopic morphology and microscopic structure. The results show that with the increase of ultrasonic amplitude, the dilution rate and wetting Angle decrease first and then increase. When the amplitude is 24 μm, the dilution rate is the lowest 25%, and the wetting Angle is the lowest 65°. The application of ultrasonic amplitude reduces the columnar crystals at the bottom of the cladding layer and changes the growth direction. As a result, the coating structure changes from coarse columnar dendrites to dendritic and equiaxial dendrites.

Finally, the wear and corrosion resistance of the Ni60 coating fabricated via ultrasonic - assisted laser cladding was investigated. The influence of ultrasonic amplitude on the properties of the coating was discussed by characterizing the microhardness, wear resistance and corrosion resistance in NaCl and H2SO4 solution. The results showed that with the introduction of ultrasound, the average microhardness of the coating increased by 45.4%, the average friction coefficient decreased by 42.9, the wear rate of the coating and the width and depth of the wear marks gradually decreased, and the wear mechanism changed from severe wear particle wear, peeling wear and adhesive wear in the absence of ultrasound to slight wear particle wear. The corrosion resistance of the cladding layer with different ultrasonic amplitudes is better than that of 3.5 wt.% H2SO4 solution, especially when the ultrasonic amplitudes reach 24 μm, the wear and corrosion resistance of the coating is the best.

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