基于NSGA-II算法的激光熔覆单道成形工艺参数多目标优化*

郭星星; 帅美荣; 王建梅; 李亚杰; 马承睿

引用本文:	郭星星,帅美荣,王建梅,李亚杰,马承睿.基于NSGA-II算法的激光熔覆单道成形工艺参数多目标优化*[J].中国表面工程,2023,36(3):87~100
	GUO Xingxing,SHUAI Meirong,WANG Jianmei,LI Yajie,MA Chengrui.Multi-objective Optimization of Laser Cladding Single-pass Forming Process Parameters Based on NSGA-II Algorithm[J].China Surface Engineering,2023,36(3):87~100

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基于NSGA-II算法的激光熔覆单道成形工艺参数多目标优化*
郭星星¹, 帅美荣¹, 王建梅¹, 李亚杰², 马承睿²
1.太原科技大学重型机械教育部工程研究中心太原 030024;2.太原科技大学材料科学与工程学院太原 030024

摘要:

激光熔覆参数设计和产品成形质量评估是多输入多输出耦合控制，但关于各参数权重配分以及多目标协同优化研究鲜有报道。设计 L16(4³ )激光单道熔覆正交试验方案，研究 27SiMn 钢表面熔覆 GS-Fe01 铁基合金粉末的最优工艺参数；通过建立以激光功率、扫描速度和送粉速率关键参数表征的优化变量，构建以熔覆层性能评估为指标的目标响应非线性数学模型；探究优化变量及其权重排序对覆层性能的影响规律。基于快速非支配排序遗传算法(NSGA-II)多目标优化的 Pareto 解集，寻求最佳参数。结果表明：在激光功率 744 W，扫描速度 233 mm / min，送粉速率 1.2 r / min 工况下，熔覆层稀释率 19.9%，宽高比 3.001，显微硬度 747.15 HV_0.5时，目标响应值匹配最佳。沿激光熔覆凝固方向，熔覆界面微观组织形貌逐步由树枝晶和柱状晶组织转换为体积小、数量多的非定向等轴晶粒。研究结果可为激光熔覆多目标工艺参数优化及复合涂层质量控制提供理论支撑。

关键词: 激光熔覆正交试验 NSGA-II 算法多目标优化

DOI：10.11933/j.issn.1007?9289.20221006001

分类号:TG456;TG665;TP18

基金项目:山西省重点研发计划(201903D121043)、轧制技术及连轧自动化国家重点实验室(东北大学)开放课题(2020RALKFKT013)、山西省先进钢铁材料重点科技创新平台建设(20201041)、常州市领军型创新人才引进培育(CQ20200042)、山西省研究生教育改革研究课题(2020YJJG241)和山西省研究生教育创新(2021Y709)资助项目

Multi-objective Optimization of Laser Cladding Single-pass Forming Process Parameters Based on NSGA-II Algorithm

GUO Xingxing¹, SHUAI Meirong¹, WANG Jianmei¹, LI Yajie², MA Chengrui²

1.Engineering Research Center Heavy Machinery Ministry of Education,Taiyuan University of Science and Technology, Taiyuan 030024 , China;2.School of Materials Science and Engineering, Taiyuan University of Science and Technology,Taiyuan 030024 , China

Abstract:

Owing to its high strength, 27SiMn steel is typically used in making the power components of the hydraulic supports of coal mine machinery. However, its surface is prone to cause wear, corrosion, and other forms of failure under harsh working environments, resulting in a hidden danger and significant resource wastage. Laser cladding technology is as an emerging re-manufacturing method that can form a surface coating with an extremely low rate of dilution, dense micro-morphology, and good metallurgical bonding. This type of technology has achieved demonstrable results in the field of surface modification and substrate material repair. Therefore, a series of studies on laser cladding were developed to improve the service life of the power components, and mainly focused on the optimization of the process parameters in this paper. 27SiMn steel and GS-Fe01 iron alloy powder were used as the substrate and surface, respectively, and an orthogonal scheme L16(4³ ) was designed for the single-pass laser cladding experiments. Additionally, a set of non-linear mathematical models were constructed and characterized by optimized variables such as the laser power, scanning speed, and powder feeding rate, and objective functions such as the dilution rate, aspect ratio, and micro-hardness. In this regard, the influence rules of the optimized variables and weight order on the cladding performance were thoroughly studied. Furthermore, using the quick non-dominated sorting genetic algorithm(NSGA-II) and solution set from Pareto, the optimal parameters of the cladding process were quickly searched and determined. The calculation results based on the established models show that the weight distribution of the process parameters and influence degree on the evaluation indicators of the cladding layer are completely different. The laser power has a positive effect on the dilution rate, aspect ratio, and micro-hardness of the cladding layer. The scanning speed has a positive effect on the dilution rate and aspect ratio, but a negative effect on the micro-hardness. While the effect law of powder feeding rate is opposite to that of scanning speed. The weight order of influence on the dilution rate is laser power ＞ scanning speed ＞ powder feeding rate, that on the aspect ratio is scanning speed ＞ laser power ＞ powder feeding rate, and that influencing the micro-hardness is powder feeding rate ＞ laser power ＞ scanning speed. According to the solution set from Pareto, a laser power of 744 W, scanning speed of 233 mm/min, and powder feeding rate of 1.2 r/min produces the optimal matching of the objective functions, that is, a dilution rate of 19.9%, an aspect ratio of 3.001, and a micro-hardness of 747.15 HV_0.5. Compared with the experimental values, the calculation deviations are 5.3%, 2.1%, and 1.6%, respectively. The experimental results also show that the micro-tissue morphology of the cladding is gradually changed from a branch and column tissue to non-directional equiaxed grains with a small size and large quantity along the freezing direction of cladding, which enhances the comprehensive performance of the cladding layer. Moreover, the micro-hardness of the substrate, heat-affected zone, and cladding layer all exhibit an increasing trend characterized by a three-level stepwise pattern, which is conducive for the stable transformation of the mechanical properties along the cladding thickness direction. Thus, these studies can provide a theoretical basis for the optimization of the multi-objective parameters of the laser cladding process, which improves the quality of the composite coating.

Key words: laser cladding orthogonal experiment NSGA-II algorithm multiple objective optimization