Analysis of the structure and properties of Ni-based alloys on the surface of 42CrMo steel with plasma cladding

Analysis of the structure and properties of Ni-based alloys on the surface of 42CrMo steel with plasma cladding | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article Analysis of the structure and properties of Ni-based alloys on the surface of 42CrMo steel with plasma cladding Hongmei Liu, Chao Li, Xiuquan Cao, Yao He, Lin Wang, Xinyang Li This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-4684981/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract As a kind of structural alloy steel, 42CrMo steel is widely used in a variety of mechanical components, especially in high-load conditions. The surface of 42CrMo steel is very unlikely to work properly in lasting bad conditions. The failure is mostly because the steel wears. And sometimes the steel cracks or even breaks. Since it is difficult to repair the steel once it fails, this paper proposes a surface repair method for 42CrMo steel based on plasma cladding technology. Firstly, using plasma cladding technology, Ni-based cladded layers were prepared on the surface of 42CrMo steel. Then, the microstructure, hardness and wear of the cladded layers were observed through specialized equipment. Finally, the effect of process parameters on the temperature of the molten pool was analyzed with the simulation software. It has been found out that the substrate is mainly compose of ferrite and pearlite and the zone affected by heat is mainly composed of coarse grains and strip grains. It has also been found that the cladded layer is composed of-Ni and-(Fe,Ni) phases, which results in a significant increase of hardness, namely from 282 HV 0.2 to 516 HV 0.2 . The average friction coefficients of the substrate and the cladded layer are 0.910 and 0.569, respectively. Correspondingly, the wear amounts are 5.39E -6 mm 3 ·N -1 ·m -1 and 2.24E -6 mm 3 ·N -1 ·m -1 , and the wear volumes are 3.88E -3 mm 3 and 1.61E -3 mm 3 . This means that the wear resistance of the cladded layer is higher than that of the substrate. With the help of analysis of simulation, it is concluded that the width and depth of the molten pool of the cladded layer grows when the current grows. The width and depth of the molten pool of the cladded layer decreases when the speed gets higher. Physical sciences/Engineering Physical sciences/Engineering/Mechanical engineering Physical sciences/Physics/Plasma physics Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Introduction 42CrMo steel is a structural alloy steel, which is generally used to manufacture important components that function in high-load conditions. Examples of such components are the cut-off teeth of coal mining machines [1], ship crankshafts [2], oil and gas drilling tools [3], the rack rails of scraper conveyors [4], the large modulus racks and pinions [5,6]. In lasting terrible conditions, the components that are made from 42CrMo steel are very likely to be damaged and fail, which largely reduces the lifespans. In addition, it consumes large amount of time and labor to replace components. In order to the increase the lifespan, scholars at home and abroad have adopted suitable approaches to modify the surface of 42CrMo steel [7]. As a result, surface coating technology, such as thermal spraying, electroplating, vapor deposition, laser cladding, and plasma cladding technology, develops [8]. Taking advantage of flame spraying, Li [9] prepared Ni60/WC coatings on the surface of 42CrMo steel and observed the structure and properties of the coatings. He found that flame spraying can improve the surface properties of the substrate effectively. Wu [10] discovered that resistance to abrasion and toughness of 42CrMo steel can be improved effectively by TiN, which is generated by the nitriding reaction with the involvement of titanium on the surface of the steel. Zhang [11] electrodeposited CoNiP on the surface of 42CrMo steel and found that the processed substrate possessed a dense surface with good crystallinity and excellent wear resistance. Luo [12] and Cheng [13] utilized laser cladding technology to process 42 CrMo steel and discovered that the wear resistance was significantly improved and the hardness was also increased by 2-3 times. Yu [14] made Ni-based coatings by plasma cladding technology, and found out that they had best overall performance. The distribution of the coatings was oven and dendritic grains were relatively small. The hardness of the coatings was 42.3% higher than that of the substrate material and the wear amount of the coatings was 74% smaller than that of the substrate material. So, the deficiencies of large modulus racks and pinions were partly fixed with Ni-based coatings. The journal surface of the rotor of the power station equipment didn’t function normally. Guo [15] repaired the surface with 316L alloy, a type of plasma arc cladding. It was discovered that the cladder layer fitted the substrate perfectly and there were no defects, such as cracks, in the cladded layer and the zone affected by heat. So, the overall performance of the compound of the cladder layer and substrate was better than that of the substrate. Ding [16] adopted the plasma cladding to create cladding on the surface of the rail substrate. And it was found that with plasma cladding technology, the microscopic structure of the cladded layer could be controlled effectively and the function of the rail substrate could be restored. Using plasma cladding, Lu [17] analyzed the effect of WC particles melting precipitation on the performance of the Ni60-cladded layer and worked out the optimal cladding current, namely 140A. Shi [18] concluded that, through plasma cladding technology, making excellent coatings on the surface of damaged components was able to activate the components and increase their lifespans, which greatly benefited enterprises economically. Laser cladding and plasma cladding can produce a quality compound of the substrate and the cladded layer. Thus, the two cladding techniques have been discussed a lot in recent years. Unfortunately, the application of laser cladding is narrow due to the high price of the equipment. Plasma cladding possesses many advantages, such as wide application, low cost, simple operation, adaptation to different environments, high quality of produced cladded layers, and has consequently been utilized in fields of aerospace, machinery, metallurgy and coal mining [19]. Plasma cladding is an advanced technology which modifies and repairs the surface. The principle of the technology is to utilize high-energy plasma jets to melt both the substrate and the metal powder on it to generate a solid metallurgical coating after rapid solidification, which greatly improves the performance of the substrate [20]. The common types of plasma cladding powder are Fe-based, Ni-based and Co-based powder. Fe-based powder is inexpensive but its resistance to oxidation is bad. Co-based powder has excellent performance but there are few varieties of it and it is costly to be produced. Ni-based powder has excellent performance and its price is reasonable, which enables it to be widely used. As plasma cladding technology developed rapidly, quite a few scholars began to adopt the method of numerical simulation to study the cladding process. Common numerical simulations are simulations of stress, flow and temperature. Numerical simulation has great significance for improving the stress, minimizing defects, improving high-energy jets cladding and forming process [21]. Most scholars focused on the simulation of jets and the simulation of stress in the cladding process [22]. For example, making use of both simulation and experiment, scholars [23] discovered the law of residual stress distribution of plasma cladding Co-based alloy, which can reduce the probability of occurrence of cracks effectively. Fang [24] simulated the electrical discharge process of the plasma based on completely non-equilibrium fluid model. Then he compared the results with experimental data and found out the characteristics of plasma electrical discharge. Peng [25] utilized COMSOL, a piece of simulation software, to simulate the temperature inside the plasma torch and compared the results with real data. The deviation is acceptable, which means the simulation is feasible. Nevertheless, few scholars have studied the temperature changes of the molten pool in the plasma cladding process or how the process parameters affect the formation of the molten pool. In the plasma cladding process, the formation of the molten pool is affected by the temperature, and adjusting process parameters has great significance for the formation of the molten pool. The depth of the molten pool affects the combination of the cladded layer and the substrate. If the molten pool is too deep, the substrate material will be melted too much, and the quality of the cladded layer will drop greatly due to the addition of over-melted substrate. If the molten pool is too shallow, a firm metallurgical mixture of the cladded layer and the substrate can not be generated, which means the hardness of the mixture is quite low. In this case, the effectiveness of plasma cladding is limited. Therefore, this paper adopted plasma cladding technology to study the organization and properties of plasma-coated Ni-based cladded layers on the surface of 42CrMo steel and the changes of the temperature of the molten pool in the plasma cladding process was simulated through ABAQUS, a simulation software, in order to analyze how process parameters influenced the formation of the molten pool. The accuracy of the simulation was verified with experiments. Materials and Methods Experimental Materials The experimental material was 42CrMo steel with a size of 100 80 10 mm. The hardness of the steel was approximately 282 HV 0.2 , and a 1 mm groove had been made on its surface for pre-positioning powder. The cladding material was Ni60A powder with a mesh size of 150-300 mesh. The substrate was ground and cleaned to remove rust and oxide, then the cladding powder and binder were mixed according to a certain ratio and the mixture was spread evenly in the groove of the substrate surface. Afterward the mixture was dried and the plasma cladding experiment was carried out. The chemical composition of 42CrMo steel and Ni60A is listed in Table 1. Table 1 Chemical composition of 42CrMo steel and Ni60A (mass fraction, wt.%). Materials C Si Mn P S O B Cr Mo Fe Ni 42CrMo 0.436 0.26 0.64 0.014 0.0031 - - 0.99 0.18 Bal - Ni60A 0.75 4.12 - - - 0.03 3.02 16.47 - 4.64 Bal Experimental Equipment As shown in Fig. 1, the experimental equipment consists of a plasma power source, a cooling subsystem, a gas supply subsystem, a three-coordinate motion system, and a laminar plasma torch. The plasma power supply converted three-phase alternating current into direct current, which is supplied to the plasma torch. The cooling unit adopts water cooling method to cool the plasma torch. The gas source utilized pure nitrogen as the working gas, with a flow rate of 11 L/min. By means of programming, the three-coordinate motion system controls the movement of the plasma torch. And the system accomplished scanning automatically according to the cladding route that had been determined. The plasma torch, which was made by the research team, had a power of 20 kW and was constitute by a cathode, an anode, an intermediate electrode, and tan arc-inducing electrode and others. Experimental Principle Plasma cladding technology, which is established based on surface treatment technologies such as laser cladding, plasma welding, is a surface treatment technique of metal [26]. By means of plasma jets, the heat source, plasma cladding technology is a surface composite layer technique which enables the surface of metal to be resistant to wear, corrosion, heat and impact [27]. The principle is that the metal substrate surface is coated with cladding powder which has particular structure, particular properties and chemical composition which is different from that of the substrate or to simultaneously transport the cladding powder. With dense plasma jets, both the cladding powder and the surface of the metal substrate were melted and formed a mixture. Through heat conduction between the substrate and air, the mixture cooled off and became a cladded layer with a metallurgical bond on the substrate surface. The essence of plasma cladding is a non-equilibrium metallurgical reaction process which involves complex chemical and physical changes [28]. Its principle is shown in Fig. 2. Experimental Methodology Experimental Methods As shown in Fig. 2, the quality of the cladded layer is affected by the jet form, the amount of the current, scanning speed. The process parameters, which are illustrated in Table 2, have been decided based on preliminary experiment. As shown in Table 3. In order to enhance the process parameters and obtain a cladded layer with better quality as well, orthogonal experiment L9 (3 3 ) is adopted to conduct the experiment. Table 2 Plasma cladding process parameters Status of the plasma jet Diameters of the outlet (mm) Working gas type Gas flow rate (L/min) Arc current (A) Cladding distance (mm) Scan velocity (mm/min) Laminar 7 Pure N 2 11 100-120 25-45 40-60 Table 3 Plasma cladding orthogonal experiments No. Arc current Cladding distance Scan velocity 1 100 25 40 2 100 35 50 3 100 45 60 4 110 25 50 5 110 35 60 6 110 45 40 7 120 25 60 8 120 35 40 9 120 45 50 Test instruments and methods After the experiment, the substrate cooled down. The cladded layer was cut by cutting equipment such as wire-cutting and a metallographic cutting machine and transformed into samples. The samples were ground mechanically and manually and were polished afterward to obtain specimens. The specimens were corroded by 5% nitric acid alcohol for 15-20 s. Then the specimens were dried and examined under a metallographic microscope. The micro-structure of the cladded layer was examined under a scanning electronic microscope. Then the cladded layer went through surface scanning energy spectrum analysis and the distribution of element was found. Using both the X-ray diffractometer and Jade software, physical analysis was accomplished with a scanning angle of 5-90°, a scanning speed of 5°/s and copper which was the chosen material. The Vickers hardness tester was employed to measure the hardness from the top of the sample cladded layer to the substrate, with a load of 200 g and a holding time of 15 s and the hardness distribution trend of the cladder layer was generated. The friction coefficient was qualitatively analyzed by a reciprocating friction and wear tester, which lasted for 60 min, with a load of 10 N, a frequency of 2 Hz. The roughness tester was utilized to measure the abraded surfaces and to calculate the abrasion amount. The appearance of the scratches’ surfaces was examined under a super-dense field 3D microscope. Finally, the thermophysical parameters of the material were calculated through JmatPro and analyzed by ABAQUS. A simulation model which was the same in size to the experimental sample was created. By means of the model, the temperature change of the molten pool in the plasma cladding process was simulated and how the process parameters affected the temperature change was studied. The accuracy of the simulation was verified by experiment. Results and Discussion Micro-structure The micro-structure of the whole cladding area is discovered by observing and is illustrated in Fig. 3. As Fig. 3(a) shows, it is relatively easy to differentiate between sub-regions and from bottom to top, the three sub-regions are the substrate, the zone that is affected by heat and the cladded layer. As shown in Fig. 3(b), the substrate mainly consists of white ferrite and black pearlite. The grains of the ferrite and pearlite are relatively fine. The existence of the zone that is affected by heat is due to the effect of high-energy jets. The jets brings about major change in the substrate’s structure and properties. Grains merged, which results in the formation of coarse and striated grains. This is illustrated in Fig. 3(c). The structure of the cladded layer is shown in Fig. 3(d). The powder was scanned by the plasma jets and integrated with the substrate in a metallurgical way to form the cladded layer. This was a heating and cooling process, which happened quickly. As the ratio of temperature gradient to solidification rate changed constantly, planar crystal, cytocrystalline, columnar crystal and equiaxial crystal appeared respectively from the bottom to the top of the cladded layer, which are shown in Fig. 4. As shown in Fig. 5, it can be clearly seen through the scanning electronic microscope that the substrate and the cladded layer are separated by a bright white stripe. The formation of the bright white stripe was because the ratio of the temperature gradient to solidification rate met the condition in which the planar crystal moved when the mixture started to solidify. Based on the results of chemical element spectral scanning analysis, it can be seen that the distribution of six chemical elements namely Fe, Ni, Cr, Si, B, and C in the cladder layer is in a gradient form with the bonding zone separating them. From the zone that is affected by heat to the central part of cladded layer, the amount of Fe decreases gradually while the amount of both Ni and Cr increases. This means in the process of plasma cladding, melted mixture powder fully integrated with the molten area of the surface of the 42CrMo steel substrate and Fe and Ni spread at the interface. A good metallurgical bond forms during the solidification following the plasma cladding, which ensures that the combination of the Ni-based cladded layer and the substrate is strong enough. Physical Phase Analysis The XRD patterns of the substrate and the cladded layer are shown in Fig. 6. In the figure, it can be seen that the main physical phases of the substrate are -(Fe,Cr), -Cr, and CrC. The composition of the Ni-based cladded layers is -Ni dendrites, inter-dendrites of -(Fe,Ni), -Cr, carbides, borides, silicides etc. Compared with the substrate, the structure of the Ni-based cladder layers is more stable and the layers are more resistant to wear. The chromium carbide is a type of the hard metal ceramics. The chromium carbide’s linear coefficient of thermal expansion is close to that of Ni and it is compatible with Ni-based substrate, so it is not easy to crack in the cladding process. Microhardness Analysis The hardness of Ni-based cladded layer and the substrate was measured by the Vickers hardness tester. The results are illustrated in Fig. 7. It can be seen that the hardness of the cladded layer is much higher than that of the substrate: The hardness of the cladded layer is approximately 516 HV 0.2 while the hardness of the substrate is approximately 282 HV 0.2 . The reason why the hardness of the cladded layer is nearly twice as high as the hardness of substrate is that the plasma cladding is a non-equilibrium solidification crystallization process in which a certain amount of supersaturated solid solution, for example -(Fe,Ni), is generated. The hardness of the cladded layer is increased due to the effect of solid solution. In addition, with the effect of the plasma jets, the metallurgical chemical reaction of the cladded layer generated enhanced phases, such as Cr 7 C 3 , Ni 4 B 3 , Ni 3 Si 2 . The enhanced phases strengthened phase transition and consequently affected the hardness of the cladder layer greatly. Furthermore, due to the effect of the heat source of the plasma jets such as laminar flow, it can be noticed that the hardness of the zone that is affected by heat is relatively high, which is around 350HV 0.2 . Friction and Wear Performance Analysis Both the friction and wear of the substrate and cladded layer was simulated by the reciprocating friction and wear tester. As illustrated in Fig. 8, the friction coefficients of the substrate and the cladded layer climb rapidly during the first 15 minutes and then fluctuate with an upward trend. The friction coefficient of the substrate is around 0.910 while that of the cladded layer is around 0.569. By calculation, the wear amounts of the substrate and the cladded layer are 5.39E -6 mm 3 ·N -1 ·m -1 , 2.24E -6 mm 3 ·N -1 ·m -1 respectively, and the wear volumes of the substrate and the cladded layer are 3.88E -3 mm 3 and 1.61E -3 mm 3 respectively. These figures are given in Fig. 9. The wear amount of the cladded layer was approximately half of that of the substrate. This is due to the much weight loss of the substrate, which is resulted in by the substrate’s low hardness and weak resistance to abrasion. The type of wear of the substrate is adhesive wear. However, affected by the solid solution effect of the plasma jet flow, the structure of the cladded layer changes. The formations of carbides, borides, silicides, and other phases could be used as hard point obstacles. The type of wear, abrasive wear, could greatly reduce the abrasion caused by abrasive particles on the surface, which means the resistance to abrasion was increased. Based on the observation of both substrate and the cladded layer, which is illustrated in Fig. 10, the scratches on the surface of the substrate are deep, wide and dense. The overall look of the scratches is like a furrow. But there are not many scratches on the surface of the cladded layer. The scratches are shallow and not continuous. So, it is concluded that the resistance to abrasion has been increased significantly. Molten Pool Temperature Simulation Fig. 11 illustrates the temperatures of the molten pool horizontally and vertically. It can be found that the powder completed melted both horizontally and vertically. A small portion of the substrate that touched the powder melted. The widths and depths of the molten pool are shown in Fig. 12. When the fixed speed was 60 mm/min, the effect of current on temperature was studied. As shown in Fig. 13, with a fixed speed, the temperature of the molten pool grows when the current increases and the temperature goes up from 2932℃ to 3220℃. Furthermore, the width and the depth both becomes bigger gradually. As illustrated in Fig. 14, with a fixed current of 120A, the effect of speed on temperature was researched. The width and depth of the molten pool drop gradually when the speed increases. And the temperature also goes down from 3332℃ to 3220℃. Fig. 15 illustrates the geometry of the molten pool when the cladding experiment was completed. It can be easily seen that both the width and depth of the molten pool grow as the current goes up. Nevertheless, the molten pool narrows when the speed increases. Table 4 is the comparison of the figures generated by simulation with the figures obtained in the experiment. The figures of simulation and experiment are roughly the same. Although errors exist, they are not significant and are acceptable. The existence of errors could result from simplification of the model during the simulation process and appropriate assumptions made. At the same time, the simulated morphology of the molten pool of the Ni-based cladded layer is compared with the actual morphology of the molten pool, as shown in Fig. 16. It can be found that the temperature partitions of the simulated morphology and the actual morphology of the two cladding materials are roughly consistent, the cladded layer area is basically consistent, and the heat-affected area is slightly consistent. Consequently, the reliability of experiment can be verified by simulation and simulation can be utilized to find out how process parameters affect temperature of the molten pool. This is meaningful in terms of plasma technology. The method of simulation may be adopted in the field of remanufacturing. Table 4 Comparison of figures of the simulation and experiment of the molten pool No. Width Depth Simulation figures Experiment figures Simulation figures Experiment figures 1 10.56 9.66 3.86 3.32 2 10.78 10.54 4.12 3.86 3 11.23 11.58 4.54 4.34 4 12.05 12.35 5.21 4.78 5 11.78 11.46 4.98 4.32 6 11.23 10.42 4.54 3.72 Conclusion In this paper, both experiment and stimulation were adopted. Through orthogonal experiment, the structure and properties of Ni-based alloys, which were generated by plasma cladding, on the surface of 42CrMo steel were analyzed. The following conclusions have been drawn: The substrate consists largely of ferrite and pearlite. The zone affected by heat consists largely of coarse grains and strip grains. And the cladded layer consists of -Ni and -(Fe,Ni) phases etc. The hardness of the cladded layer increased from 282HV 0.2 to 516HV 0.2, which is nearly twice that of the substrate. The average friction coefficients of the substrate and the cladded layer are 0.910 and 0.644 respectively. The wear amounts of the substrate and the cladded layer are 5.39E -6 mm 3 ·N -1 ·m -1 and 2.24E -6 mm 3 ·N -1 ·m -1 respectively. And the wear volumes are 3.88E -3 mm 3 and 1.61E -3 mm 3 respectively. Therefore, the wear resistance of the cladded layer is higher than that of the substrate. The temperature variations were simulated successfully and the simulation was verified by experiment. With I = 120 A, V = 60 mm/min, the molten pool has its highest temperature, 3220℃. The simulation demonstrates how process parameters affect the temperature of the molten pool. With a fixed speed, the width and depth of the molten pool grows when the current increases. With a fixed current, the width and depth of the molten drops when the speed increases. Declarations CRediT authorship contribution statement Hongmei Liu: Conceptualization, Methodology, Investigation, Writing-Original Draft Preparation. Chao Li: Validation, Writing-Review & Editing, Resources. Xiuquan Cao: Project Administration, Resources, Funding Acquisition. Yao He: Validation, Formal Analysis, Supervision. Lin Wang: Investigation, Methodology, Data Curation. Xinyang Li: Investigation, Visualization, Software. Competing interests The author(s) declare no competing interests. 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Li, Analyses on the nonequilibrium transport processes in a free-burning argon arc plasma under different operating conditions, IOP Publishing(1): 15015, https://doi.org/10.1088/1361-6595/ac2c8d. L. Peng, P.Y. Wang, J.W. Wang, Numerical Simulation of DC Arc Plasma Torch, Aerospace Shanghai(Chinese & English), 2023, 40(4): 73-79, https://doi.org/10.19328/j.cnki.2096-8655.2023.04.010. J.F. Li, Study on Laser Cladding Fe-based Anti-wear Coatings on the Middle Chute in Scraper Conveyor, China University of Mining and Technology, 2022, https://doi.org/10.27623/d.cnki.gzkyu.2022.001048. W.J. Gu, Research on Remanufacturing Technology,microstructure and Performance of Rail Transit Train Wheel Sets, Anhui University of Engineering,2023, https://doi.org/10.27763/d.cnki.gahgc.2022.000054. D.W. Luo, Study on Preparation and Properties of TiC/Ni Composite Coatings by Plasma Cladding on 42CrMoA Steel, Harbin Engineering University,2018, https://doi.org/ CNKI:CDMD:2.1018.290061. Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. 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Li","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAvElEQVRIiWNgGAWjYBACPmYGNgiLvbHx4QditLDBtfAcbjaWIEoLA0yLRHqbAA9RWtiZnz34UVEnb3DzYRuDBIOdnG4DQYexmRv2nDlsuOF2YtuDAoZkY7MDBLXwsEnwth1IMLid2G4gwXAgcRsxWiT/ttUlGNw82CbBQ6wWad425gSDG4xEa2Ezk5YB+mXmmURgIBsQ4Rd+/sPPJN8AQ4zv+PGHDz9U2MkR1IIGDEhTPgpGwSgYBaMABwAAmh4501AfyzgAAAAASUVORK5CYII=","orcid":"","institution":"Chengdu University of Technology","correspondingAuthor":true,"prefix":"","firstName":"Chao","middleName":"","lastName":"Li","suffix":""},{"id":333886649,"identity":"a6a57175-4e21-4604-8f59-59478edec12e","order_by":2,"name":"Xiuquan Cao","email":"","orcid":"","institution":"Sichuan University of Science \u0026 Engneering","correspondingAuthor":false,"prefix":"","firstName":"Xiuquan","middleName":"","lastName":"Cao","suffix":""},{"id":333886650,"identity":"9e88336c-acc1-44bb-95ee-6a3481a1ecfb","order_by":3,"name":"Yao He","email":"","orcid":"","institution":"Yibin University","correspondingAuthor":false,"prefix":"","firstName":"Yao","middleName":"","lastName":"He","suffix":""},{"id":333886651,"identity":"41ff74aa-87d3-457d-af3c-f56326c0920f","order_by":4,"name":"Lin Wang","email":"","orcid":"","institution":"Sichuan University of Science \u0026 Engneering","correspondingAuthor":false,"prefix":"","firstName":"Lin","middleName":"","lastName":"Wang","suffix":""},{"id":333886652,"identity":"8040f151-d241-4298-842c-4eb3fe6d81c8","order_by":5,"name":"Xinyang Li","email":"","orcid":"","institution":"Chengdu University of Technology","correspondingAuthor":false,"prefix":"","firstName":"Xinyang","middleName":"","lastName":"Li","suffix":""}],"badges":[],"createdAt":"2024-07-04 08:31:44","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-4684981/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-4684981/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":61515893,"identity":"416fb89f-9984-463a-9b0e-6883662a67ac","added_by":"auto","created_at":"2024-07-31 15:48:32","extension":"png","order_by":1,"title":"Figure 1","display":"","copyAsset":false,"role":"figure","size":38401,"visible":true,"origin":"","legend":"\u003cp\u003eA diagram of the experimental setup\u003c/p\u003e","description":"","filename":"1.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/243f2af27011a6ef9771cbec.png"},{"id":61514563,"identity":"a60507aa-f94e-4ee8-8092-298fa08dbd2f","added_by":"auto","created_at":"2024-07-31 15:32:32","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":40764,"visible":true,"origin":"","legend":"\u003cp\u003ePlasma cladding principle\u003c/p\u003e","description":"","filename":"2.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/14ac9eb3a4566cd064b4ccca.png"},{"id":61514565,"identity":"4207cfd5-36f7-4e2c-8553-230e2945355c","added_by":"auto","created_at":"2024-07-31 15:32:32","extension":"png","order_by":3,"title":"Figure 3","display":"","copyAsset":false,"role":"figure","size":501985,"visible":true,"origin":"","legend":"\u003cp\u003eMetallographic structure of the entire cladding area\u003c/p\u003e","description":"","filename":"3.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/d9240d6fab6bc0197f129c0b.png"},{"id":61515198,"identity":"1e79cb0a-b242-42fb-9f9a-9d6300d72462","added_by":"auto","created_at":"2024-07-31 15:40:32","extension":"png","order_by":4,"title":"Figure 4","display":"","copyAsset":false,"role":"figure","size":564335,"visible":true,"origin":"","legend":"\u003cp\u003eMetallographic structure of the cladded layer\u003c/p\u003e","description":"","filename":"4.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/e351fd7bc5c511677e9f7723.png"},{"id":61515895,"identity":"3336a5e4-1bac-411e-83f0-d534b4d646d5","added_by":"auto","created_at":"2024-07-31 15:48:32","extension":"png","order_by":5,"title":"Figure 5","display":"","copyAsset":false,"role":"figure","size":904424,"visible":true,"origin":"","legend":"\u003cp\u003eEDS analytical results of the cladded layer (chemical element energy spectrum sweep)\u003c/p\u003e","description":"","filename":"5.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/81aba1ec1d1bf6e493bbb1a9.png"},{"id":61515894,"identity":"c9406ba3-2816-4e45-9717-b85aff36fa08","added_by":"auto","created_at":"2024-07-31 15:48:32","extension":"png","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":76211,"visible":true,"origin":"","legend":"\u003cp\u003eXRD patterns of the substrate and the cladded layer\u003c/p\u003e","description":"","filename":"6.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/e6888a53047206a91bc00bc4.png"},{"id":61514566,"identity":"cb3367ba-ef37-45d3-807c-97c6f6f5c52c","added_by":"auto","created_at":"2024-07-31 15:32:32","extension":"png","order_by":7,"title":"Figure 7","display":"","copyAsset":false,"role":"figure","size":33450,"visible":true,"origin":"","legend":"\u003cp\u003eMicro-hardness of the substrate and the cladded layer\u003c/p\u003e","description":"","filename":"7.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/fefb0dfc825c56a753071997.png"},{"id":61514573,"identity":"740216ac-cea6-4505-8414-a7f52c6a903d","added_by":"auto","created_at":"2024-07-31 15:32:32","extension":"png","order_by":8,"title":"Figure 8","display":"","copyAsset":false,"role":"figure","size":19606,"visible":true,"origin":"","legend":"\u003cp\u003eFriction coefficients of the substrate and the cladded layer\u003c/p\u003e","description":"","filename":"8.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/401e81e59389906bc36d59f3.png"},{"id":61514570,"identity":"112c87ab-18d4-4978-8537-c4abb5114e58","added_by":"auto","created_at":"2024-07-31 15:32:32","extension":"png","order_by":9,"title":"Figure 9","display":"","copyAsset":false,"role":"figure","size":19209,"visible":true,"origin":"","legend":"\u003cp\u003eWeight Loss of the substrate and the cladded layer\u003c/p\u003e","description":"","filename":"9.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/11d9ecfa203fc433b98626b1.png"},{"id":61515203,"identity":"b7090324-bbd6-4911-b891-add530c1ae94","added_by":"auto","created_at":"2024-07-31 15:40:32","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":265227,"visible":true,"origin":"","legend":"\u003cp\u003eScratches on the surfaces of the substrate and the cladded layer\u003c/p\u003e","description":"","filename":"10.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/f664658c782fcec721bdd015.png"},{"id":61514575,"identity":"1e1d3613-09d3-4b8a-8f58-7f6921c4d09f","added_by":"auto","created_at":"2024-07-31 15:32:33","extension":"png","order_by":11,"title":"Figure 11","display":"","copyAsset":false,"role":"figure","size":137147,"visible":true,"origin":"","legend":"\u003cp\u003eThe variation in temperature of the molten pool\u003c/p\u003e","description":"","filename":"11.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/8ac7a07b8f3dc500566e3247.png"},{"id":61515200,"identity":"5b917b2a-32c6-48f6-ad80-73b82052eb28","added_by":"auto","created_at":"2024-07-31 15:40:32","extension":"png","order_by":12,"title":"Figure 12","display":"","copyAsset":false,"role":"figure","size":27954,"visible":true,"origin":"","legend":"\u003cp\u003eWidth and depth of the molten pool\u003c/p\u003e","description":"","filename":"12.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/0d7b8c0a146b16da1d343034.png"},{"id":61515202,"identity":"b5fe9578-cb81-41b2-8c26-9611437d6233","added_by":"auto","created_at":"2024-07-31 15:40:32","extension":"png","order_by":13,"title":"Figure 13","display":"","copyAsset":false,"role":"figure","size":39253,"visible":true,"origin":"","legend":"\u003cp\u003eEffect of currents on the molten pool temperature\u003c/p\u003e\n\u003cp\u003e(a) In the horizontal direction; (b) In the vertical direction\u003c/p\u003e","description":"","filename":"13.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/05a7a9826a55f6596c93a5da.png"},{"id":61514567,"identity":"395a6701-a4dd-4c52-b066-100240e7343b","added_by":"auto","created_at":"2024-07-31 15:32:32","extension":"png","order_by":14,"title":"Figure 14","display":"","copyAsset":false,"role":"figure","size":43459,"visible":true,"origin":"","legend":"\u003cp\u003eEffect of velocity on the molten pool temperature\u003c/p\u003e\n\u003cp\u003e(a) In the horizontal direction; (b) In the vertical direction\u003c/p\u003e","description":"","filename":"14.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/d8666d0cf950763a6b4ea0d8.png"},{"id":61514576,"identity":"15780c2a-484c-4468-93b2-493239f73cd9","added_by":"auto","created_at":"2024-07-31 15:32:33","extension":"png","order_by":15,"title":"Figure 15","display":"","copyAsset":false,"role":"figure","size":382614,"visible":true,"origin":"","legend":"\u003cp\u003eGeometry of the molten pool\u003c/p\u003e","description":"","filename":"15.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/9300acecf4ce3869545323b6.png"},{"id":61514572,"identity":"98e7e8c6-9595-4ea3-b2a9-13094a83cdfa","added_by":"auto","created_at":"2024-07-31 15:32:32","extension":"png","order_by":16,"title":"Figure 16","display":"","copyAsset":false,"role":"figure","size":33800,"visible":true,"origin":"","legend":"\u003cp\u003eComparison of simulated and actual melt pool topography\u003c/p\u003e","description":"","filename":"16.png","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/cb8a6ceef587e8509be14306.png"},{"id":67384051,"identity":"e3733b32-1018-4c49-9465-423cf481a74b","added_by":"auto","created_at":"2024-10-24 09:46:56","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":4096479,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-4684981/v1/6eb62e3f-f34c-4bad-89de-81b9aa3e7de0.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Analysis of the structure and properties of Ni-based alloys on the surface of 42CrMo steel with plasma cladding","fulltext":[{"header":"Introduction","content":"\u003cp\u003e42CrMo steel is a structural alloy steel, which is generally used to manufacture important components that function in high-load conditions. Examples of such components are the cut-off teeth of coal mining machines\u0026nbsp;[1], ship crankshafts\u0026nbsp;[2], oil and gas drilling tools\u0026nbsp;[3], the rack rails of scraper conveyors\u0026nbsp;[4], the large modulus racks and pinions\u0026nbsp;[5,6].\u0026nbsp;In lasting terrible conditions, the components that are made from 42CrMo steel are very likely to be damaged and fail, which largely reduces the lifespans. In addition, it consumes large amount of time and labor to replace components.\u003c/p\u003e\n\u003cp\u003eIn order to the increase the lifespan, scholars at home and abroad have adopted suitable approaches to modify the surface of 42CrMo steel\u0026nbsp;[7]. As a result, surface coating technology, such as thermal spraying, electroplating, vapor deposition, laser cladding, and plasma cladding technology, develops\u0026nbsp;[8]. Taking advantage of flame spraying, Li\u0026nbsp;[9]\u0026nbsp;prepared Ni60/WC coatings on the surface of 42CrMo steel and observed the structure and properties of the coatings. He found that flame spraying can improve the surface properties of the substrate effectively.\u0026nbsp;Wu\u0026nbsp;[10]\u0026nbsp;discovered that resistance to abrasion and toughness of 42CrMo steel can be improved effectively by TiN, which is generated by the nitriding reaction with the involvement of titanium on the surface of the steel.\u0026nbsp;Zhang\u0026nbsp;[11]\u0026nbsp;electrodeposited CoNiP on the surface of 42CrMo steel and found that the processed substrate possessed a dense surface with good crystallinity and excellent wear resistance. Luo\u0026nbsp;[12]\u0026nbsp;and Cheng\u0026nbsp;[13]\u0026nbsp;utilized laser cladding technology to process 42 CrMo steel and discovered that the wear resistance was significantly improved and the hardness was also increased by 2-3 times.\u0026nbsp;Yu\u0026nbsp;[14]\u0026nbsp;made Ni-based coatings by plasma cladding technology, and found out that they had best overall performance. The distribution of the coatings was oven and dendritic grains were relatively small. The hardness of the coatings was 42.3% higher than that of the substrate material and the wear amount of the coatings was 74% smaller than that of the substrate material. So, the deficiencies of large modulus racks and pinions were partly fixed with Ni-based coatings. The journal surface of the rotor of the power station equipment didn’t function normally. Guo\u0026nbsp;[15]\u0026nbsp;repaired the surface with 316L alloy, a type of plasma arc cladding. It was discovered that the cladder layer fitted the substrate perfectly and there were no defects, such as cracks, in the cladded layer and the zone affected by heat. So, the overall performance of the compound of the cladder layer and substrate was better than that of the substrate. Ding\u0026nbsp;[16]\u0026nbsp;adopted the plasma cladding to create cladding on the surface of the rail substrate. And it was found that with plasma cladding technology, the microscopic structure of the cladded layer could be controlled effectively and the function of the rail substrate could be restored. Using plasma cladding, Lu\u0026nbsp;[17]\u0026nbsp;analyzed the effect of WC particles melting precipitation on the performance of the Ni60-cladded layer and worked out the optimal cladding current, namely 140A. Shi [18] concluded that, through plasma cladding technology, making excellent coatings on the surface of damaged components was able to activate the components and increase their lifespans, which greatly benefited enterprises economically.\u003c/p\u003e\n\u003cp\u003eLaser cladding and plasma cladding can produce a quality compound of the substrate and the cladded layer. Thus, the two cladding techniques have been discussed a lot in recent years. Unfortunately, the application of laser cladding is narrow due to the high price of the equipment. Plasma cladding possesses many advantages, such as wide application, low cost, simple operation, adaptation to different environments, high quality of produced cladded layers, and has consequently been utilized in fields of aerospace, machinery, metallurgy and coal mining [19].\u003c/p\u003e\n\u003cp\u003ePlasma cladding is an advanced technology which modifies and repairs the surface. The principle of the technology is to utilize high-energy plasma jets to melt both the substrate and the metal powder on it to generate a solid metallurgical coating after rapid solidification, which greatly improves the performance of the substrate\u0026nbsp;[20]. The common types of plasma cladding powder are Fe-based, Ni-based and Co-based powder. Fe-based powder is inexpensive but its resistance to oxidation is bad. Co-based powder has excellent performance but there are few varieties of it and it is costly to be produced. Ni-based powder has excellent performance and its price is reasonable, which enables it to be widely used.\u003c/p\u003e\n\u003cp\u003eAs plasma cladding technology developed rapidly, quite a few scholars began to adopt the method of numerical simulation to study the cladding process. Common numerical simulations are simulations of stress, flow and temperature. Numerical simulation has great significance for improving the stress, minimizing defects, improving high-energy jets cladding and forming process [21]. Most scholars focused on the simulation of jets and the simulation of stress in the cladding process\u0026nbsp;[22]. For example, making use of both simulation and experiment, scholars\u0026nbsp;[23]\u0026nbsp;discovered the law of residual stress distribution of plasma cladding Co-based alloy, which can reduce the probability of occurrence of cracks effectively. Fang\u0026nbsp;[24]\u0026nbsp;simulated the electrical discharge process of the plasma based on completely non-equilibrium fluid model. Then he compared the results with experimental data and found out the characteristics of plasma electrical discharge. Peng [25] utilized COMSOL, a piece of simulation software, to simulate the temperature inside the plasma torch and compared the results with real data. The deviation is acceptable, which means the simulation is feasible.\u0026nbsp;\u003c/p\u003e\n\u003cp\u003eNevertheless, few scholars have studied the temperature changes of the molten pool in the plasma cladding process or how the process parameters affect the formation of the molten pool. In the plasma cladding process, the formation of the molten pool is affected by the temperature, and adjusting process parameters has great significance for the formation of the molten pool. The depth of the molten pool affects the combination of the cladded layer and the substrate. If the molten pool is too deep, the substrate material will be melted too much, and the quality of the cladded layer will drop greatly due to the addition of over-melted substrate. If the molten pool is too shallow, a firm metallurgical mixture of the cladded layer and the substrate can not be generated, which means the hardness of the mixture is quite low. In this case, the effectiveness of plasma cladding is limited.\u003c/p\u003e\n\u003cp\u003eTherefore, this paper adopted plasma cladding technology to study the organization and properties of plasma-coated Ni-based cladded layers on the surface of 42CrMo steel and the changes of the temperature of the molten pool in the plasma cladding process was simulated through ABAQUS, a simulation software, in order to analyze how process parameters influenced the formation of the molten pool. The accuracy of the simulation was verified with experiments.\u003c/p\u003e"},{"header":"Materials and Methods","content":"\u003ch2\u003eExperimental Materials\u003c/h2\u003e\n\u003cp\u003eThe experimental material was 42CrMo steel with a size of 100\u0026nbsp;80\u0026nbsp;10 mm. The hardness of the steel was approximately 282 HV\u003csub\u003e0.2\u003c/sub\u003e, and a 1 mm groove had been made on its surface for pre-positioning powder. The cladding material was Ni60A powder with a mesh size of 150-300 mesh. The substrate was ground and cleaned to remove rust and oxide, then the cladding powder and binder were mixed according to a certain ratio and the mixture was spread evenly in the groove of the substrate surface. Afterward the mixture was dried and the plasma cladding experiment was carried out. The chemical composition of 42CrMo steel and Ni60A is listed in Table 1.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eTable 1\u0026nbsp;\u003c/strong\u003eChemical composition of 42CrMo steel and Ni60A (mass fraction, wt.%).\u003c/p\u003e\n\u003ctable border=\"1\" cellspacing=\"0\" cellpadding=\"0\"\u003e\n \u003ctbody\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.972972972972974%\"\u003e\n \u003cp\u003eMaterials\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"8.82882882882883%\"\u003e\n \u003cp\u003eC\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003eSi\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003eMn\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"8.82882882882883%\"\u003e\n \u003cp\u003eP\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"10.09009009009009%\"\u003e\n \u003cp\u003eS\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003eO\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003eB\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"8.82882882882883%\"\u003e\n \u003cp\u003eCr\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003eMo\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.387387387387387%\"\u003e\n \u003cp\u003eFe\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"5.225225225225225%\" valign=\"top\"\u003e\n \u003cp\u003eNi\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.972972972972974%\"\u003e\n \u003cp\u003e42CrMo\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"8.82882882882883%\"\u003e\n \u003cp\u003e0.436\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e0.26\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e0.64\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"8.82882882882883%\"\u003e\n \u003cp\u003e0.014\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"10.09009009009009%\"\u003e\n \u003cp\u003e0.0031\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e-\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e-\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"8.82882882882883%\"\u003e\n \u003cp\u003e0.99\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e0.18\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.387387387387387%\"\u003e\n \u003cp\u003eBal\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"5.225225225225225%\" valign=\"top\"\u003e\n \u003cp\u003e-\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.972972972972974%\"\u003e\n \u003cp\u003eNi60A\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"8.82882882882883%\"\u003e\n \u003cp\u003e0.75\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e4.12\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e-\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"8.82882882882883%\"\u003e\n \u003cp\u003e-\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"10.09009009009009%\"\u003e\n \u003cp\u003e-\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e0.03\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e3.02\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"8.82882882882883%\"\u003e\n \u003cp\u003e16.47\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.5675675675675675%\"\u003e\n \u003cp\u003e-\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"7.387387387387387%\"\u003e\n \u003cp\u003e4.64\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"5.225225225225225%\" valign=\"top\"\u003e\n \u003cp\u003eBal\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003c/tbody\u003e\n\u003c/table\u003e\n\u003ch2\u003eExperimental Equipment\u003c/h2\u003e\n\u003cp\u003eAs shown in Fig. 1, the experimental equipment consists of a plasma power source, a cooling subsystem, a gas supply subsystem, a three-coordinate motion system, and a laminar plasma torch. The plasma power supply converted three-phase alternating current into direct current, which is supplied to the plasma torch. The cooling unit adopts water cooling method to cool the plasma torch. The gas source utilized pure nitrogen as the working gas, with a flow rate of 11 L/min. By means of programming, the three-coordinate motion system controls the movement of the plasma torch. And the system accomplished scanning automatically according to the cladding route that had been determined. The plasma torch, which was made by the research team, had a power of 20 kW and was constitute by a cathode, an anode, an intermediate electrode, and tan arc-inducing electrode and others.\u003c/p\u003e\n\u003ch2\u003eExperimental Principle\u003c/h2\u003e\n\u003cp\u003ePlasma cladding technology, which is established based on surface treatment technologies such as laser cladding, plasma welding, is a surface treatment technique of metal [26].\u0026nbsp;\u003c/p\u003e\n\u003cp\u003eBy means of plasma jets, the heat source, plasma cladding technology is a surface composite layer technique which enables the surface of metal to be resistant to wear, corrosion, heat and impact [27]. The principle is that the metal substrate surface is coated with cladding powder which has particular structure, particular properties and chemical composition which is different from that of the substrate or to simultaneously transport the cladding powder. With dense plasma jets, both the cladding powder and the surface of the metal substrate were melted and formed a mixture. Through heat conduction between the substrate and air, the mixture cooled off and became a cladded layer with a metallurgical bond on the substrate surface. The essence of plasma cladding is a non-equilibrium metallurgical reaction process which involves complex chemical and physical changes [28]. Its principle is shown in Fig. 2.\u003c/p\u003e\n\u003ch2\u003eExperimental Methodology\u003c/h2\u003e\n\u003ch3\u003eExperimental Methods\u003c/h3\u003e\n\u003cp\u003eAs shown in Fig. 2, the quality of the cladded layer is affected by the jet form, the amount of the current, scanning speed. The process parameters, which are illustrated in Table 2, have been decided based on preliminary experiment. As shown in Table 3. In order to enhance the process parameters and obtain a cladded layer with better quality as well, orthogonal experiment L9 (3\u003csup\u003e3\u003c/sup\u003e) is adopted to conduct the experiment.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eTable 2\u0026nbsp;\u003c/strong\u003ePlasma cladding process parameters\u003c/p\u003e\n\u003ctable border=\"1\" cellspacing=\"0\" cellpadding=\"0\" width=\"605\"\u003e\n \u003ctbody\u003e\n \u003ctr\u003e\n \u003ctd width=\"15.702479338842975%\"\u003e\n \u003cp\u003eStatus of the plasma jet\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"17.1900826446281%\"\u003e\n \u003cp\u003eDiameters of the outlet (mm)\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"10.909090909090908%\"\u003e\n \u003cp\u003eWorking gas type\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"14.049586776859504%\"\u003e\n \u003cp\u003eGas flow rate (L/min)\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"10.909090909090908%\"\u003e\n \u003cp\u003eArc current (A)\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"15.702479338842975%\"\u003e\n \u003cp\u003eCladding distance (mm)\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"15.537190082644628%\"\u003e\n \u003cp\u003eScan velocity (mm/min)\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"15.702479338842975%\"\u003e\n \u003cp\u003eLaminar\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"17.1900826446281%\"\u003e\n \u003cp\u003e7\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"10.909090909090908%\"\u003e\n \u003cp\u003ePure N\u003csub\u003e2\u003c/sub\u003e\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"14.049586776859504%\"\u003e\n \u003cp\u003e11\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"10.909090909090908%\"\u003e\n \u003cp\u003e100-120\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"15.702479338842975%\"\u003e\n \u003cp\u003e25-45\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"15.537190082644628%\"\u003e\n \u003cp\u003e40-60\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003c/tbody\u003e\n\u003c/table\u003e\n\u003cp\u003e\u003cstrong\u003e\u003cbr\u003e\u003c/strong\u003e\u003cstrong\u003eTable 3\u0026nbsp;\u003c/strong\u003ePlasma cladding orthogonal experiments\u003c/p\u003e\n\u003ctable border=\"1\" cellspacing=\"0\" cellpadding=\"0\" width=\"293\"\u003e\n \u003ctbody\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\"\u003e\n \u003cp\u003eNo.\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\"\u003e\n \u003cp\u003eArc current\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"32.081911262798634%\"\u003e\n \u003cp\u003eCladding distance\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"29.01023890784983%\" colspan=\"2\"\u003e\n \u003cp\u003eScan velocity\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\" valign=\"top\"\u003e\n \u003cp\u003e1\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\" valign=\"top\"\u003e\n \u003cp\u003e100\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"40.61433447098976%\" colspan=\"2\" valign=\"top\"\u003e\n \u003cp\u003e25\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.477815699658702%\" valign=\"top\"\u003e\n \u003cp\u003e40\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\" valign=\"top\"\u003e\n \u003cp\u003e2\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\" valign=\"top\"\u003e\n \u003cp\u003e100\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"40.61433447098976%\" colspan=\"2\" valign=\"top\"\u003e\n \u003cp\u003e35\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.477815699658702%\" valign=\"top\"\u003e\n \u003cp\u003e50\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\" valign=\"top\"\u003e\n \u003cp\u003e3\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\" valign=\"top\"\u003e\n \u003cp\u003e100\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"40.61433447098976%\" colspan=\"2\" valign=\"top\"\u003e\n \u003cp\u003e45\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.477815699658702%\" valign=\"top\"\u003e\n \u003cp\u003e60\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\" valign=\"top\"\u003e\n \u003cp\u003e4\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\" valign=\"top\"\u003e\n \u003cp\u003e110\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"40.61433447098976%\" colspan=\"2\" valign=\"top\"\u003e\n \u003cp\u003e25\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.477815699658702%\" valign=\"top\"\u003e\n \u003cp\u003e50\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\" valign=\"top\"\u003e\n \u003cp\u003e5\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\" valign=\"top\"\u003e\n \u003cp\u003e110\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"40.61433447098976%\" colspan=\"2\" valign=\"top\"\u003e\n \u003cp\u003e35\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.477815699658702%\" valign=\"top\"\u003e\n \u003cp\u003e60\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\" valign=\"top\"\u003e\n \u003cp\u003e6\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\" valign=\"top\"\u003e\n \u003cp\u003e110\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"40.61433447098976%\" colspan=\"2\" valign=\"top\"\u003e\n \u003cp\u003e45\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.477815699658702%\" valign=\"top\"\u003e\n \u003cp\u003e40\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\" valign=\"top\"\u003e\n \u003cp\u003e7\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\" valign=\"top\"\u003e\n \u003cp\u003e120\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"40.61433447098976%\" colspan=\"2\" valign=\"top\"\u003e\n \u003cp\u003e25\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.477815699658702%\" valign=\"top\"\u003e\n \u003cp\u003e60\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\" valign=\"top\"\u003e\n \u003cp\u003e8\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\" valign=\"top\"\u003e\n \u003cp\u003e120\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"40.61433447098976%\" colspan=\"2\" valign=\"top\"\u003e\n \u003cp\u003e35\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.477815699658702%\" valign=\"top\"\u003e\n \u003cp\u003e40\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"11.945392491467576%\" valign=\"top\"\u003e\n \u003cp\u003e9\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"26.962457337883958%\" valign=\"top\"\u003e\n \u003cp\u003e120\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"40.61433447098976%\" colspan=\"2\" valign=\"top\"\u003e\n \u003cp\u003e45\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.477815699658702%\" valign=\"top\"\u003e\n \u003cp\u003e50\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003c/tbody\u003e\n\u003c/table\u003e\n\u003ch3\u003eTest instruments and methods\u003c/h3\u003e\n\u003cp\u003eAfter the experiment, the substrate cooled down. The cladded layer was cut by cutting equipment such as wire-cutting and a metallographic cutting machine and transformed into samples. The samples were ground mechanically and manually and were polished afterward to obtain specimens. The specimens were corroded by 5% nitric acid alcohol for 15-20 s. Then the specimens were dried and examined under a metallographic microscope. The micro-structure of the cladded layer was examined under a scanning electronic microscope. Then the cladded layer went through surface scanning energy spectrum analysis and the distribution of element was found. Using both the X-ray diffractometer and Jade software, physical analysis was accomplished with a scanning angle of 5-90\u0026deg;, a scanning speed of 5\u0026deg;/s and copper which was the chosen material. The Vickers hardness tester was employed to measure the hardness from the top of the sample cladded layer to the substrate, with a load of 200 g and a holding time of 15 s and the hardness distribution trend of the cladder layer was generated. The friction coefficient was qualitatively analyzed by a reciprocating friction and wear tester, which lasted for 60 min, with a load of 10 N, a frequency of 2 Hz. The roughness tester was utilized to measure the abraded surfaces and to calculate the abrasion amount. The appearance of the scratches\u0026rsquo; surfaces was examined under a super-dense field 3D microscope. Finally, the thermophysical parameters of the material were calculated through JmatPro and analyzed by ABAQUS. A simulation model which was the same in size to the experimental sample was created. By means of the model, the temperature change of the molten pool in the plasma cladding process was simulated and how the process parameters affected the temperature change was studied. The accuracy of the simulation was verified by experiment.\u003c/p\u003e"},{"header":"Results and Discussion","content":"\u003ch2\u003eMicro-structure\u003c/h2\u003e\n\u003cp\u003eThe micro-structure of the whole cladding area is discovered by observing and is illustrated in Fig. 3. As Fig. 3(a) shows, it is relatively easy to differentiate between sub-regions and from bottom to top, the three sub-regions are the substrate, the zone that is affected by heat and the cladded layer. As shown in Fig. 3(b), the substrate mainly consists of white ferrite and black pearlite. The grains of the ferrite and pearlite are relatively fine. The existence of the zone that is affected by heat is due to the effect of high-energy jets. The jets brings about major change in the substrate\u0026rsquo;s structure and properties. Grains merged, which results in the formation of coarse and striated grains. This is illustrated in Fig. 3(c). The structure of the cladded layer is shown in Fig. 3(d).\u0026nbsp;\u003c/p\u003e\n\u003cp\u003eThe powder was scanned by the plasma jets and integrated with the substrate in a metallurgical way to form the cladded layer. This was a heating and cooling process, which happened quickly. As the ratio of temperature gradient to solidification rate changed constantly, planar crystal, cytocrystalline, columnar crystal and equiaxial crystal appeared respectively from the bottom to the top of the cladded layer, which are shown in Fig. 4.\u003c/p\u003e\n\u003cp\u003eAs shown in Fig. 5, it can be clearly seen through the scanning electronic microscope that the substrate and the cladded layer are separated by a bright white stripe. The formation of the bright white stripe was because the ratio of the temperature gradient to solidification rate met the condition in which the planar crystal moved when the mixture started to solidify.\u0026nbsp;\u003c/p\u003e\n\u003cp\u003eBased on the results of chemical element spectral scanning analysis, it can be seen that the distribution of six chemical elements namely Fe, Ni, Cr, Si, B, and C in the cladder layer is in a gradient form with the bonding zone separating them. From the zone that is affected by heat to the central part of cladded layer, the amount of Fe decreases gradually while the amount of both Ni and Cr increases. This means in the process of plasma cladding, melted mixture powder fully integrated with the molten area of the surface of the 42CrMo steel substrate and Fe and Ni spread at the interface. A good metallurgical bond forms during the solidification following the plasma cladding, which ensures that the combination of the Ni-based cladded layer and the substrate is strong enough.\u003c/p\u003e\n\u003ch2\u003ePhysical Phase Analysis\u003c/h2\u003e\n\u003cp\u003eThe XRD patterns of the substrate and the cladded layer are shown in Fig. 6. In the figure, it can be seen that the main physical phases of the substrate are \u0026nbsp;-(Fe,Cr), \u0026nbsp;-Cr, and CrC. The composition of the Ni-based cladded layers is \u0026nbsp;-Ni dendrites, inter-dendrites of \u0026nbsp;-(Fe,Ni), \u0026nbsp;-Cr, carbides, borides, silicides etc. Compared with the substrate, the structure of the Ni-based cladder layers is more stable and the layers are more resistant to wear. The chromium carbide is a type of the hard metal ceramics. The chromium carbide\u0026rsquo;s linear coefficient of thermal expansion is close to that of Ni and it is compatible with Ni-based substrate, so it is not easy to crack in the cladding process.\u003c/p\u003e\n\u003ch2\u003eMicrohardness Analysis\u003c/h2\u003e\n\u003cp\u003eThe hardness of Ni-based cladded layer and the substrate was measured by the Vickers hardness tester. The results are illustrated in Fig. 7. It can be seen that the hardness of the cladded layer is much higher than that of the substrate: The hardness of the cladded layer is approximately 516 HV\u003csub\u003e0.2\u0026nbsp;\u003c/sub\u003ewhile the hardness of the substrate is approximately 282 HV\u003csub\u003e0.2\u003c/sub\u003e. The reason why the hardness of the cladded layer is nearly twice as high as the hardness of substrate is that the plasma cladding is a non-equilibrium solidification crystallization process in which a certain amount of supersaturated solid solution, for example \u0026nbsp;-(Fe,Ni), is generated. The hardness of the cladded layer is increased due to the effect of solid solution. In addition, with the effect of the plasma jets, the metallurgical chemical reaction of the cladded layer generated enhanced phases, such as Cr\u003csub\u003e7\u003c/sub\u003eC\u003csub\u003e3\u003c/sub\u003e, Ni\u003csub\u003e4\u003c/sub\u003eB\u003csub\u003e3\u003c/sub\u003e, Ni\u003csub\u003e3\u003c/sub\u003eSi\u003csub\u003e2\u003c/sub\u003e. The enhanced phases strengthened phase transition and consequently affected the hardness of the cladder layer greatly. Furthermore, due to the effect of the heat source of the plasma jets such as laminar flow, it can be noticed that the hardness of the zone that is affected by heat is relatively high, which is around 350HV\u003csub\u003e0.2\u003c/sub\u003e.\u003c/p\u003e\n\u003ch2\u003eFriction and Wear Performance Analysis\u003c/h2\u003e\n\u003cp\u003eBoth the friction and wear of the substrate and cladded layer was simulated by the reciprocating friction and wear tester. As illustrated in Fig. 8, the friction coefficients of the substrate and the cladded layer climb rapidly during the first 15 minutes and then fluctuate with an upward trend. The friction coefficient of the substrate is around 0.910 while that of the cladded layer is around 0.569. By calculation, the wear amounts of the substrate and the cladded layer are\u0026nbsp;5.39E\u003csup\u003e-6\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e\u0026middot;N\u003csup\u003e-1\u003c/sup\u003e\u0026middot;m\u003csup\u003e-1\u003c/sup\u003e, 2.24E\u003csup\u003e-6\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e\u0026middot;N\u003csup\u003e-1\u003c/sup\u003e\u0026middot;m\u003csup\u003e-1\u0026nbsp;\u003c/sup\u003erespectively, and the wear volumes of\u0026nbsp;the substrate and the cladded layer are 3.88E\u003csup\u003e-3\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e and 1.61E\u003csup\u003e-3\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e respectively. These figures are given in Fig. 9. The wear amount of the cladded layer was approximately half of that of the substrate. This is due to the much weight loss of the substrate, which is resulted in by the substrate\u0026rsquo;s low hardness and weak resistance to abrasion. The type of wear of the substrate is adhesive wear. However, affected by the solid solution effect of the plasma jet flow, the structure of the cladded layer changes. The formations of carbides, borides, silicides, and other phases could be used as hard point obstacles. The type of wear, abrasive wear, could greatly reduce the abrasion caused by abrasive particles on the surface, which means the resistance to abrasion was increased. Based on the observation of both substrate and the cladded layer, which is illustrated in Fig. 10, the scratches on the surface of the substrate are deep, wide and dense. The overall look of the scratches is like a furrow. But there are not many scratches on the surface of the cladded layer. The scratches are shallow and not continuous. So, it is concluded that the resistance to abrasion has been increased significantly.\u003c/p\u003e\n\u003ch2\u003eMolten Pool Temperature Simulation\u003c/h2\u003e\n\u003cp\u003eFig. 11 illustrates the temperatures of the molten pool horizontally and vertically. It can be found that the powder completed melted both horizontally and vertically. A small portion of the substrate that touched the powder melted. The widths and depths of the molten pool are shown in Fig. 12. When the fixed speed was 60 mm/min, the effect of current on temperature was studied. As shown in Fig. 13, with a fixed speed, the temperature of the molten pool grows when the current increases and the temperature goes up from 2932℃ to 3220℃. Furthermore, the width and the depth both becomes bigger gradually. As illustrated in Fig. 14, with a fixed current of 120A, the effect of speed on temperature was researched. The width and depth of the molten pool drop gradually when the speed increases. And the temperature also goes down from 3332℃ to 3220℃.\u003c/p\u003e\n\u003cp\u003eFig. 15 illustrates the geometry of the molten pool when the cladding experiment was completed. It can be easily seen that both the width and depth of the molten pool grow as the current goes up. Nevertheless, the molten pool narrows when the speed increases. Table 4 is the comparison of the figures generated by simulation with the figures obtained in the experiment. The figures of simulation and experiment are roughly the same. Although errors exist, they are not significant and are acceptable. The existence of errors could result from simplification of the model during the simulation process and appropriate assumptions made.\u003c/p\u003e\n\u003cp\u003eAt the same time, the simulated morphology of the molten pool of the Ni-based cladded layer is compared with the actual morphology of the molten pool, as shown in Fig. 16. It can be found that the temperature partitions of the simulated morphology and the actual morphology of the two cladding materials are roughly consistent, the cladded layer area is basically consistent, and the heat-affected area is slightly consistent. Consequently, the reliability of experiment can be verified by simulation and simulation can be utilized to find out how process parameters affect temperature of the molten pool. This is meaningful in terms of plasma technology. The method of simulation may be adopted in the field of remanufacturing.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eTable 4\u0026nbsp;\u003c/strong\u003eComparison of figures of the simulation and experiment of the molten pool\u003c/p\u003e\n\u003ctable border=\"0\" cellspacing=\"0\" cellpadding=\"0\"\u003e\n \u003ctbody\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.152777777777779%\" rowspan=\"2\"\u003e\n \u003cp\u003eNo.\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"44.44444444444444%\" colspan=\"2\"\u003e\n \u003cp\u003eWidth\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"43.40277777777778%\" colspan=\"2\"\u003e\n \u003cp\u003eDepth\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"25%\"\u003e\n \u003cp\u003eSimulation figures\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"25.793650793650794%\"\u003e\n \u003cp\u003eExperiment figures\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"23.41269841269841%\"\u003e\n \u003cp\u003eSimulation figures\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"25.793650793650794%\"\u003e\n \u003cp\u003eExperiment figures\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.195121951219512%\"\u003e\n \u003cp\u003e1\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"21.951219512195124%\"\u003e\n \u003cp\u003e10.56\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e9.66\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.557491289198605%\"\u003e\n \u003cp\u003e3.86\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e3.32\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.195121951219512%\"\u003e\n \u003cp\u003e2\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"21.951219512195124%\"\u003e\n \u003cp\u003e10.78\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e10.54\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.557491289198605%\"\u003e\n \u003cp\u003e4.12\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e3.86\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.195121951219512%\"\u003e\n \u003cp\u003e3\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"21.951219512195124%\"\u003e\n \u003cp\u003e11.23\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e11.58\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.557491289198605%\"\u003e\n \u003cp\u003e4.54\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e4.34\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.195121951219512%\"\u003e\n \u003cp\u003e4\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"21.951219512195124%\"\u003e\n \u003cp\u003e12.05\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e12.35\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.557491289198605%\"\u003e\n \u003cp\u003e5.21\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e4.78\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.195121951219512%\"\u003e\n \u003cp\u003e5\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"21.951219512195124%\"\u003e\n \u003cp\u003e11.78\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e11.46\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.557491289198605%\"\u003e\n \u003cp\u003e4.98\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e4.32\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003ctr\u003e\n \u003ctd width=\"12.195121951219512%\"\u003e\n \u003cp\u003e6\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"21.951219512195124%\"\u003e\n \u003cp\u003e11.23\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e10.42\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"20.557491289198605%\"\u003e\n \u003cp\u003e4.54\u003c/p\u003e\n \u003c/td\u003e\n \u003ctd width=\"22.64808362369338%\"\u003e\n \u003cp\u003e3.72\u003c/p\u003e\n \u003c/td\u003e\n \u003c/tr\u003e\n \u003c/tbody\u003e\n\u003c/table\u003e"},{"header":"Conclusion","content":"\u003cp\u003eIn this paper, both experiment and stimulation were adopted. Through orthogonal experiment, the structure and properties of Ni-based alloys, which were generated by plasma cladding, on the surface of 42CrMo steel were analyzed. The following conclusions have been drawn:\u003c/p\u003e\n\u003col\u003e\n \u003cli\u003eThe substrate consists largely of ferrite and pearlite. The zone affected by heat consists largely of coarse grains and strip grains. And the cladded layer consists of\u0026nbsp;\u0026nbsp;-Ni and\u0026nbsp;-(Fe,Ni) phases etc.\u0026nbsp;\u003c/li\u003e\n \u003cli\u003eThe hardness of the cladded layer increased from 282HV\u003csub\u003e0.2\u003c/sub\u003e to 516HV\u003csub\u003e0.2,\u0026nbsp;\u003c/sub\u003ewhich is\u0026nbsp;nearly twice that of the substrate.\u0026nbsp;The average friction coefficients of the substrate and the cladded layer are 0.910 and 0.644 respectively. The wear amounts of the substrate and the cladded layer are\u0026nbsp;5.39E\u003csup\u003e-6\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e·N\u003csup\u003e-1\u003c/sup\u003e·m\u003csup\u003e-1\u003c/sup\u003e and 2.24E\u003csup\u003e-6\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e·N\u003csup\u003e-1\u003c/sup\u003e·m\u003csup\u003e-1\u003c/sup\u003e respectively. And the wear volumes are 3.88E\u003csup\u003e-3\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e and 1.61E\u003csup\u003e-3\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e respectively. Therefore, the wear resistance of the cladded layer is higher than that of the substrate.\u0026nbsp;\u003c/li\u003e\n \u003cli\u003eThe temperature variations were simulated successfully and the simulation was verified by experiment. With \u003cem\u003eI\u0026nbsp;\u003c/em\u003e= 120 A,\u0026nbsp;\u003cem\u003eV\u0026nbsp;\u003c/em\u003e= 60 mm/min, the molten pool has its highest temperature, 3220℃. The simulation demonstrates how process parameters affect the temperature of the molten pool. With a fixed speed, the width and depth of the molten pool grows when the current increases. With a fixed current, the width and depth of the molten drops when the speed increases.\u003c/li\u003e\n\u003c/ol\u003e"},{"header":"Declarations","content":"\u003cp\u003eCRediT authorship contribution statement\u003c/p\u003e\n\u003col\u003e\n \u003cli\u003e\u003cstrong\u003eHongmei Liu:\u003c/strong\u003e Conceptualization, Methodology, Investigation,\u0026nbsp;Writing-Original Draft Preparation.\u003c/li\u003e\n \u003cli\u003e\u003cstrong\u003eChao Li:\u003c/strong\u003e Validation,\u0026nbsp;Writing-Review \u0026amp; Editing,\u0026nbsp;Resources.\u003c/li\u003e\n \u003cli\u003e\u003cstrong\u003eXiuquan Cao:\u003c/strong\u003e Project Administration, Resources,\u0026nbsp;Funding Acquisition.\u003c/li\u003e\n \u003cli\u003e\u003cstrong\u003eYao He:\u0026nbsp;\u003c/strong\u003eValidation,\u0026nbsp;Formal Analysis, Supervision.\u003c/li\u003e\n \u003cli\u003e\u003cstrong\u003eLin Wang:\u003c/strong\u003e Investigation, Methodology, Data Curation.\u003c/li\u003e\n \u003cli\u003e\u003cstrong\u003eXinyang Li:\u003c/strong\u003e Investigation, Visualization, Software.\u003c/li\u003e\n\u003c/ol\u003e\n\u003cp\u003eCompeting interests\u003c/p\u003e\n\u003cp\u003eThe author(s) declare no competing interests.\u003c/p\u003e\n\u003cp\u003eData availability statement\u003c/p\u003e\n\u003cp\u003eData will be made available on request. For additional details regarding data acquisition, interested parties may contact the corresponding author.\u003c/p\u003e\n\u003cp\u003eAcknowledgments\u003c/p\u003e\n\u003cp\u003eThe authors appreciate the supports of the Key Laboratory of Mechanical Structure Optimization \u0026amp; Material Application Technology of Luzhou (No.SCHYZSA-2022-02).\u003c/p\u003e"},{"header":"References","content":"\u003col\u003e\n \u003cli\u003eE.P Li, Experimental Study on Laser Cladding Surface Strengthening of 42CrMo Cutting Pick, Taiyuan University of Technology, 2023, https://doi.org/10.27352/d.cnki.gylgu.2022.000209.\u003c/li\u003e\n \u003cli\u003eC. Cui, Study on the Optimization of Laser Cladding Technology for Cobalt-Based Coatings on 42CrMo Steel Surface, Jiangnan University, 2022, https://doi.org/10.27169/d.cnki.gwqgu.2021.000988.\u003c/li\u003e\n \u003cli\u003eC. Cui, M.P. Wu, S.H. 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Luo, Study on Preparation and Properties of TiC/Ni Composite Coatings by Plasma Cladding on 42CrMoA Steel, Harbin Engineering University,2018, https://doi.org/ CNKI:CDMD:2.1018.290061.\u003c/li\u003e\n\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"","lastPublishedDoi":"10.21203/rs.3.rs-4684981/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-4684981/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eAs a kind of structural alloy steel, 42CrMo steel is widely used in a variety of mechanical components, especially in high-load conditions. The surface of 42CrMo steel is very unlikely to work properly in lasting bad conditions. The failure is mostly because the steel wears. And sometimes the steel cracks or even breaks. Since it is difficult to repair the steel once it fails, \u0026nbsp;this paper proposes a surface repair method for 42CrMo steel based on plasma cladding technology. Firstly, using plasma cladding technology, Ni-based cladded layers were prepared on the surface of 42CrMo steel. Then, the microstructure, hardness and wear of the cladded layers were observed through specialized equipment. Finally, the effect of process parameters on the temperature of the molten pool was analyzed with the simulation software. It has been found out that the substrate is mainly compose of ferrite and pearlite and the zone affected by heat is mainly composed of coarse grains and strip grains. It has also been found that the cladded layer is composed of-Ni and-(Fe,Ni) phases, which results in a significant increase of hardness, namely from 282 HV\u003csub\u003e0.2\u003c/sub\u003e to 516 HV\u003csub\u003e0.2\u003c/sub\u003e. The average friction coefficients of the substrate and the cladded layer are 0.910 and 0.569, respectively. Correspondingly, the wear amounts are 5.39E\u003csup\u003e-6\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e·N\u003csup\u003e-1\u003c/sup\u003e·m\u003csup\u003e-1\u003c/sup\u003e and 2.24E\u003csup\u003e-6\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e·N\u003csup\u003e-1\u003c/sup\u003e·m\u003csup\u003e-1\u003c/sup\u003e, and the wear volumes are 3.88E\u003csup\u003e-3\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e and 1.61E\u003csup\u003e-3\u003c/sup\u003e mm\u003csup\u003e3\u003c/sup\u003e. This means that the wear resistance of the cladded layer is higher than that of the substrate. With the help of analysis of simulation, it is concluded that the width and depth of the molten pool of the cladded layer grows when the current grows. The width and depth of the molten pool of the cladded layer decreases when the speed gets higher.\u003c/p\u003e","manuscriptTitle":"Analysis of the structure and properties of Ni-based alloys on the surface of 42CrMo steel with plasma cladding","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2024-07-31 15:32:28","doi":"10.21203/rs.3.rs-4684981/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"3b344c56-28e0-4a0b-b3a1-fed5583ecac5","owner":[],"postedDate":"July 31st, 2024","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[{"id":35359117,"name":"Physical sciences/Engineering"},{"id":35359118,"name":"Physical sciences/Engineering/Mechanical engineering"},{"id":35359119,"name":"Physical sciences/Physics/Plasma physics"}],"tags":[],"updatedAt":"2024-10-24T09:38:47+00:00","versionOfRecord":[],"versionCreatedAt":"2024-07-31 15:32:28","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-4684981","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-4684981","identity":"rs-4684981","version":["v1"]},"buildId":"qtupq5eGEP_6zYnWcrvyt","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}