Cutting of Ni-base Alloy Spray Welded Layers
Ni-base alloy spray deposition technique is a widely used method for surface modification and coatings. It is commonly used to achieve a high degree of toughness and wear resistance, as well as to repair and increase the corrosion resistance of materials. The process of cutting Ni-base alloy spray welded layers is complicated and requires knowledge of the properties of the alloys and of the surface coating processes. This article will discuss the various cutting methods used to cut Ni-base alloy spray welded layers.
Basic Process
Ni-base alloy spray welded layers are first metalized with a metal-bonding flux. This flux allows for better metal-to-metal bonding and prevents the formation of oxides. The metal-bonding flux is designed to meet the specific requirements of the application, such as composition and size of the metalized part. After the Ni-base alloy has been metalized, it is heated to sinter the alloy. The heated Ni-base alloy is then sprayed onto the surface of the part by a nozzle. The resulting Ni-base alloy spray welded layer can be made to any thickness between 0.001 and 0.035 inches which is suitable for most engineering applications.
The preparation of the Ni-base alloy spray welded layer is an important step in the cutting process. It includes welding the base layer to the substrate of the part, cleaning the layer of contaminants, and using a mask to protect the areas that should not be sprayed. The prepared layer is then ready for cutting with a variety of methods.
Cutting Methods
The most common methods of cutting Ni-base alloy spray welded layers are abrasive cutting, laser cutting, and gas cutting. Abrasive cutting is the simplest and least expensive method and requires the use of an abrasive wheel or belt. The wheel is held in contact with the surface of the layer and the material is removed by the grinding action of the abrasive. This method is best suited to the cutting of straight lines and can be used for cutting materials up to 0.035 inches thick.
Laser cutting is an efficient method for cutting Ni-base alloy spray welded layers. This process uses a laser beam to heat the material and a gas to blow away the melted material. Laser cutting can produce complex shapes and can be used to cut materials up to 0.065 inches thick.
Gas cutting is a highly efficient method of cutting Ni-base alloy spray welded layers which uses a combination of oxygen and a cutting gas such as acetylene or propane. The oxygen and cutting gas react to produce a flame which melts the Ni-base alloy spray welded layer. The heat of the flame melts the material which is then removed by a cutting nozzle. This process can be used to cut materials up to 0.098 inches thick.
Conclusion
Cutting Ni-base alloy spray welded layers is a complex process that requires knowledge of the properties of the alloys and the surface coating processes. The most common methods of cutting Ni-base alloy spray welded layers are abrasive cutting, laser cutting, and gas cutting. Each of these methods has advantages and disadvantages and the selection of the best method for a particular application should be made after careful consideration.
