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The positive effect of plasma electrolytic treatment on CrWMn tool steel to increase the wear resistance of its surface is shown. The effect of plasma electrolytic nitriding and subsequent polishing on the structure, phase and elemental composition, microhardness of the surface layer, and surface morphology is established. Steel nitriding leads to the formation of a modified surface layer including Fe2–3N iron nitride and nitrogen martensite, below which hardening martensite is formed, reaching a microhardness value of 1200 HV. Subsequent polishing leads to a decrease in surface roughness by 42–68%. Tribological tests were carried out according to the shaft-bushing scheme. A decrease in the friction coefficient and weight wear of up to 2.6 and 30.1 times, respectively, is shown. The formed structure of the surface layer compensates for the effect of the counter body and determines the destruction of friction bonds by plastic displacement. The wear mechanism has been established and is defined as fatigue wear under dry friction and plastic contact. [ABSTRACT FROM AUTHOR]

Zr57Cu15Ni10Nb5 (more known as Vit-106) is a promising zirconium-based alloy with a high glass-forming ability, and belongs to the so-called bulk metallic glasses (BMG). Workpieces with a size of around one centimeter in all three dimensions can be obtained from a BMG alloy by casting. However, further increasing the cast size decreases the cooling rate and thus induces crystallization. Selective laser melting (SLM) is a well-known technique to overcome size limitations for BMGs because a workpiece is built by the addition of multiple melt portions in which the cooling rate is kept above the critical one. Currently, BMG parts obtained by SLM suffer from partial crystallization. The present work studies the influence of SLM process parameters on the partial crystallization of Vit-106 by metallography and the influence of the microstructure on mechanical properties by microhardness and wear resistance testing. Submicron crystalline inclusions are observed in an amorphous matrix of a Vit-106 alloy obtained by SLM. The size and the concentration of the inclusions can be controlled by varying the laser scanning speed. It is shown that submicron crystalline inclusions formed in the amorphous matrix during SLM can favorably affect microhardness and wear resistance. [ABSTRACT FROM AUTHOR]

In modern aviation production, innovative hard-to-machine materials with unique physical and mechanical properties are being used increasingly. When processing such materials, the weakest link in the technological chain of production is the metal-cutting tool. In this paper, to improve the efficiency of the blade cutting of heat-resistant alloys, we propose the use of nanostructured multilayer wear-resistant coatings with subsequent laser processing of the cutting surfaces of the end milling cutters according to various schemes. In this case, an increase in the wear-resistant properties of the cutting edge by 15%–20% is provided due to the formation, at high temperatures, of secondary structures with increased wear resistance and a reduction of the temperature and force loading of contact processes. Methodologically, the work was carried out in several consecutive stages: the first stage was the determination of effective grades of wear-resistant coatings obtained via various installations with their subsequent laser processing during the «SharpMark™ Fiber» installation; at the second stage tribotechnical tests were carried out during the tribometer and adhesion installation; and in the third stage wear-resistant, temperature-force tests were carried out using milling machines in various cutting modes. According to the results of the field tests, the tool durability period was increased by 15%–20%. [ABSTRACT FROM AUTHOR]

The paper presents the results of optical diagnostics of evaporation and displacement of powder fractions during the formation of a single track in the process of selective laser melting. The velocity of the powder fractions is estimated. It was defined, that an increase in the scanning speed leads to an decrease in the particle coming out rate from the molten pool and the rate at which they are attracted. The results allow evaluating the kinetics of the mass-transfer process during selective laser melting. It was clearly shown the material quality properties after the selective laser melting are strongly influenced by the formed thermal field in the laser-irradiated zone.

Gas-phase flows occurring in a plume in a processing zone during selective laser melting (SLM) can significantly affect the quality of the process. To further enhance SLM performance, the characteristics of the flows should be considered. In this article, the vapor-gas jet emerging from the laser processing zone was studied. It was visualized by interferometry to evaluate flow velocity, geometry and changes in refractory index depending on laser power. The velocity and pressure fields of the vapor jet and the entrained ambient gas were estimated by mathematical modeling. It was shown that the increase of laser power led to higher jet velocity and greater change in its refractory index. The latter also was used to evaluate the content of metal vapor in the plume and its influence on the absorption of laser radiation. [ABSTRACT FROM AUTHOR]

Phase composition and microstructure of initial WC, BK8 (powder alloy 92 wt.% WC-8 wt.% Co), Co powders, ball-milled powders with four different compositions (1) 25 wt.% WC-75 wt.% Co, (2) 30 wt.% BK8-70 wt.% Co, (3) 50 wt.% WC-50 wt.% Co, (4) 94 wt.% WC-6 wt.% Co, and bulk alloys obtained by selective laser melting (SLM) from as-milled powders in as-melted state and after heat treatment were investigated by scanning electron microscopy and X-ray diffraction analysis. Initial and ball-milled powders consist of WC, hexagonal a-Co and face-centered cubic b-Co. The SLM leads to the formation of major new phases W3Co3C, W4Co2C and face-centered cubic b-Co-based solid solution. During the heat treatment, there occurs partial decomposition of the face-centered cubic b-Co-based solid solution with the formation of W2C and hexagonal a-Co solid solution. The microstructure of obtained bulk samples, in general, corresponds to the observed phase composition. [ABSTRACT FROM AUTHOR]