Investigation of the effect of laser remelting parameters on the adhesion strength of plasma coatings to the substrate
DOI:
https://doi.org/10.31359/2311-441X-2025-27-18Keywords:
plasma coatings, laser remelting, adhesion, adhesion strength, laser beam speed, track overlap coefficientAbstract
The paper considers the features of plasma coating formation followed by laser beam remelting. Compared with plasma coatings without remelting, such coatings exhibit significantly increased adhesion strength to the substrate.
The problem of forming a strong bond between the coating and the substrate is addressed through the investigation of adhesion interaction, as it is the determining factor for the service performance of component surfaces. The determination of quantitative relationships and the evaluation of physicochemical processes occurring in the contact zone between the coating and the substrate, which lead to achieving the required adhesion strength, enable the development of theoretically substantiated technological recommendations using the principles of quantum mechanics. It is substantiated that the measure of interatomic bonding forces in a solid is the bonding energy, which adequately explains adhesion strength. The adhesion energy was calculated using an energy-based approach to evaluate metallic, covalent, and ionic bonds between the atoms of the substrate and the coating. When considering individual atoms and molecules, the dominant role belongs to exchange interaction, which is caused by the energy arising between molten coating atoms and substrate metal atoms and constitutes the determining component of the total bonding energy of two force centers.
Theoretical studies and experimentally obtained adhesion strength values made it possible to determine optimal laser processing modes under which complete welding of the plasma coating to the substrate occurs as a result of complete dissociation of oxide films on the substrate surface. The maximum adhesion strength value of σₐ = 180 MPa (for plasma coatings with laser remelting) was achieved at a minimum laser beam scanning speed of 0.8 × 10⁻³ m/s, a laser beam diameter at the interaction zone of 1 × 10 ⁻³ m, and a laser track overlap coefficient of 0.9. With an increase in the laser beam speed to 6 × 10⁻³ m/s at constant beam diameter and track overlap coefficient, the adhesion strength decreases to σₐ = 100 MPa, which is associated with a reduction in the laser remelting exposure time.
A theoretical model of interaction in the “coating–substrate” system was developed and analyzed. Its analysis makes it possible to evaluate the process of forming a strong metallic bond, substantiate the application of coatings based on self-fluxing iron-based alloy powders, and predict adhesion strength taking into account the calculated adhesion energy.
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