Recent advancements in laser cladding technology are promising significant enhancements in the wear resistance of scraper conveyor systems used within underground mining operations. Researchers have successfully developed and tested a new Fe60/WC composite coating utilizing ultrasonic-assisted laser cladding on 16Mn steel, aimed at addressing the challenge of friction and wear failure found at the middle groove of scraper conveyors.
Underground, scraper conveyors are subjected to harsh conditions, where friction between components leads to accelerated wear and reduced service life. The research, led by Jing Li and Xiaofei Wang, has emerged as part of efforts to improve the lifespan and performance of these systems. The authors utilized ultrasonic-assisted laser cladding technology, which not only enhances the coating's bonding strength but also its resistance to wear.
The methodology involved the use of 1.8 kW laser power combined with specific parameters like scanning speed of 4 mm/s and ultrasonic vibration frequency of 24 kHz to achieve optimal results. The team prepared Fe60/WC composite powders by mixing Fe60 and WC materials, with the WC component comprising 20% of the total mass. Through tests, they found the resulting coating exhibited properties desirable for industrial applications, including increased microhardness and reduced wear characteristics.
The microstructure of the cladded layer showed impressive results, featuring fewer surface imperfections such as cracks and low dilution rates at around 14.8%. The initial findings suggested the coating was able to decrease the average friction coefficient from approximately 0.66 for non-ultrasonic coatings down to 0.58 for those with ultrasonic assistance. This reduction indicates enhanced wear resistance, attributed to the finer microstructure caused by ultrasonic vibrations which, as noted, accelerate the melting and flow of materials.
While testing, the researchers applied loads between 0 to 200 N over two hours to analyze the wear rates under various conditions. The results showcased the ultrasonic-assisted coating's potential, significantly outperforming traditional cladding methods and demonstrating its applicability to extend the service life of scraper conveyor systems.
Not only do these findings highlight the performance benefits of ultrasonic-assisted laser cladding, but they also provide insights for future material enhancements targeting other wear-prone equipment within the mining sector.
Further investigations on the long-term performance of these coatings under practical operational conditions will be required. This research not only contributes to the field of surface engineering but also suggests pathways for advancing wear-resistant materials and optimizing surface-hardening technologies. The authors of the article concluded, "this study offers theoretical foundations for the development of wear-resistant materials and enhances surface-hardening technology." This highlights the foundational work necessary to realize effective solutions for the mining industry's persistent challenges.