Development of laser felling modes of gas-thermal coating
Authors: Bakhteev I. S. , Oleinik K. I. , Shak A. V. , Furman E. L. , Valiev R. M. , Vopneruk A. A. 
Published: October 2024

The use of copper and its alloys to create parts for metallurgical equipment is associated with an increase in abrasive wear and high-temperature corrosion. In this regard, there is a need to apply a protective coating. In particular, to prevent wear and premature chipping of the metal of copper tuyeres, the surface is hardened with a coating of zirconium dioxide stabilized with yttria oxide by thermal spraying in an air atmosphere. Due to the difference in the coefficient of thermal expansion of copper (at T = 300 K: 16.7 µm/m оС and at T = 750 K: 19.7 µm/m оС) and its low resistance to gas corrosion, the application of zirconium oxide (produced by a preapplied intermediate layer that plays a role in matching the coefficient of thermal expansion (CTE) between the copper base and the ceramic coating. In addition, the intermediate layer protects copper from gas corrosion. In this case, The use of copper and its alloys to create parts for metallurgical equipment is associated with an increase in abrasive wear and high-temperature corrosion. In this regard, there is a need to apply a protective coating. In particular, to prevent wear and premature chipping of the metal of copper tuyeres, the surface is hardened with a coating of zirconium dioxide stabilized with yttria oxide by thermal spraying in an air atmosphere. Due to the difference in the coefficient of thermal expansion of copper (at T = 300 K: 16.7 pm/m °G and at T = 750 K: 19.7 pm/m оG) and its low resistance to gas corrosion, the application of zirconium oxide (produced by a pre-applied intermediate layer that plays a role in matching the coefficient of thermal expansion (CTE) between the copper base and the ceramic coating. In addition, the intermediate layer protects copper from gas corrosion. In this case, nickel-based alloys were used as intermediate layers. The use of nickel as the basis of intermediate layers is due to the fact that copper and nickel form a continuous series of solid solutions, such as cupronickel or monel metal-like structures. This, in turn, assumes a smooth transition of thermophysical properties from copper to nickel alloy. To ensure increased adhesion of the transition layer to copper by increasing the area of mutual contact between copper and the sublayer (dagger penetration) and significantly increasing the homogeneity of the material of the intermediate layer made of a nickel alloy, laser melting of the intermediate sublayer (Ni–B–Si system) was used on a laser complex based on laser LS-5 with a power of 5 kW with a KUKA KR-60HA robot in an argon atmosphere. To test the modes, experiments were carried out on copper samples of a flat shape and a body of rotation. The optimal parameters for the process of melting flat samples were: processing speed 33 mm/s, power from 400 to 3900 W, focal length from 200 to 230 mm, pitch between tracks: 0.25, 0.5 and 1 mm. The optimal parameters for the process of melting rotating samples were: laser radiation power 400–450 W, processing step 0.125; 0.5, focal length from 200 to 210 mm.