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Figure 1. SEM image of Ni60 alloy powder: (a) geometry shape of Ni60, (b) size statistic of Ni60.
Figure 1. SEM image of Ni60 alloy powder: (a) geometry shape of Ni60, (b) size statistic of Ni60.
Figure 2. The schematic diagram of the LC experiment device.
Figure 2. The schematic diagram of the LC experiment device.
Figure 3. LC morphology of single channel and geometric feature.
Figure 3. LC morphology of single channel and geometric feature.
Figure 4. Schematic diagram of lapping model: (a) transverse overlapping, (b) longitudinal overlapping.
Figure 4. Schematic diagram of lapping model: (a) transverse overlapping, (b) longitudinal overlapping.
Figure 5. Deposition strategies’ optimization of the gear tooth: (I-1) hot lap joint, (I-2) cold lap joint, (I-3) optimized cold strategy, (II-1) co-directional scanning, (II-2) reverse scanning, (III-1) interlayer scanning perpendicular to the axial direction, (III-2) interlayer scanning parallel to the axial direction, (III-3) scanning directions of the two adjacent layers are perpendicular to each other.
Figure 5. Deposition strategies’ optimization of the gear tooth: (I-1) hot lap joint, (I-2) cold lap joint, (I-3) optimized cold strategy, (II-1) co-directional scanning, (II-2) reverse scanning, (III-1) interlayer scanning perpendicular to the axial direction, (III-2) interlayer scanning parallel to the axial direction, (III-3) scanning directions of the two adjacent layers are perpendicular to each other.
Figure 6. Analysis of the orthogonal experiment.
Figure 6. Analysis of the orthogonal experiment.
Figure 7. The interaction of the four parameters.
Figure 7. The interaction of the four parameters.
Figure 8. Transverse overlapping.
Figure 8. Transverse overlapping.
Figure 9. Micrograph of the cross-section of the longitudinal lap.
Figure 9. Micrograph of the cross-section of the longitudinal lap.
Figure 10. Morphologies of deposition layers under different lapping strategies: (a) Strategy I-1, (b) Strategy I-2, (c) Strategy I-3.
Figure 10. Morphologies of deposition layers under different lapping strategies: (a) Strategy I-1, (b) Strategy I-2, (c) Strategy I-3.
Figure 11. Morphologies of deposition layers under different scanning strategies: (a1) Strategy II-1, (a2) enlarged view of a1, (a3) 3D morphology of a2, (b1) Strategy II-2, (b2) enlarged view of b1, (b3) 3D morphology of b2.
Figure 11. Morphologies of deposition layers under different scanning strategies: (a1) Strategy II-1, (a2) enlarged view of a1, (a3) 3D morphology of a2, (b1) Strategy II-2, (b2) enlarged view of b1, (b3) 3D morphology of b2.
Figure 12. Morphologies of deposition layers under different deposition strategies: (a) Strategy III-1, (b) Strategy III-2, (c) Strategy III-3, (d) Errors owing to incomplete filling.
Figure 12. Morphologies of deposition layers under different deposition strategies: (a) Strategy III-1, (b) Strategy III-2, (c) Strategy III-3, (d) Errors owing to incomplete filling.
Figure 13. The machining process of gear teeth.
Figure 13. The machining process of gear teeth.
Figure 14. XRD results of the repaired zone.
Figure 14. XRD results of the repaired zone.
Figure 15. The cross-section micrographs and EDS image of the whole gear teeth.
Figure 15. The cross-section micrographs and EDS image of the whole gear teeth.
Figure 16. Microhardness and indentation morphologies of the gear teeth.
Figure 16. Microhardness and indentation morphologies of the gear teeth.
Figure 17. The friction coefficient of the substrate, Ni-based coating.
Figure 17. The friction coefficient of the substrate, Ni-based coating.
Figure 18. 3D morphologies of wear tracks of (a1) 3D worn surface of Ni60 gear teeth, (a2) corresponding section profile in zone a1, (b1) 3D worn surface of 20CrMnTi substrate, (b2) corresponding section profile in zone (b1).
Figure 18. 3D morphologies of wear tracks of (a1) 3D worn surface of Ni60 gear teeth, (a2) corresponding section profile in zone a1, (b1) 3D worn surface of 20CrMnTi substrate, (b2) corresponding section profile in zone (b1).
Figure 19. Optical images of worn surfaces (a-1) 2D worn surface morphologies of repaired gear teeth, (a-2) height graph of a-1, (a-3) enlarged view of a-1. (b-1) 2D worn surface morphologies of 20CrMnTi substrate, (b-2) height graph of b-1, (b-3) enlarged view of b-1.
Figure 19. Optical images of worn surfaces (a-1) 2D worn surface morphologies of repaired gear teeth, (a-2) height graph of a-1, (a-3) enlarged view of a-1. (b-1) 2D worn surface morphologies of 20CrMnTi substrate, (b-2) height graph of b-1, (b-3) enlarged view of b-1.
Table 1. The component of Ni60 and 20CrMnTi (wt. %).
Table 1. The component of Ni60 and 20CrMnTi (wt. %).
ElementCSiMnCrNiBFe20CrMnTi0.17–0.230.17–0.370.80–0.101.00–1.30≤0.030-Bal.Ni600.54.5-1.8Bal.315Table 2. Design and results of the orthogonal experiment.
Table 2. Design and results of the orthogonal experiment.
No.P (W)Vs (mm/s)Vp (r/min)Q (L/min)βW/H136060.480.47584.1131236080.670.18543.15863360100.860.03542.1342438060.470.16142.6136538080.660.03792.01026380100.880.47265.5973740060.680.49463.8984840080.870.24173.22929400100.460.05302.14731036060.860.42468.90341136080.480.47504.055712360100.670.17043.75001338060.660.514211.42341438080.880.32224.429515380100.470.22003.45871640060.870.18612.48111740080.460.685418.154818400100.680.40785.3525Table 3. Design and results of interaction experiment.
Table 3. Design and results of interaction experiment.
No.QVSQ × VSPQ × PVS × PVPQ × VPVS × VPP × VPβ178.51370110.601110.342278.51370110.702220.298378.51380220.601120.308478.51380220.702210.351579.52370120.601210.289679.52370120.702120.287779.52380210.601220.297879.52380210.702110.30197.58.52370210.602110.187107.58.52370210.701220.165117.58.52380120.602120.207127.58.52380120.701210.190137.59.51370220.602210.205147.59.51370220.701120.170157.59.51380110.602220.240167.59.51380110.701110.264Table 4. The results of the orthogonal experiment.
Table 4. The results of the orthogonal experiment.
P (W)VS (mm/s)VP (r/min)Q (L/min)RankΙ0.295 0.376 0.345 0.292 The rank of βTable 5. Results of the interactive experiment.
Table 5. Results of the interactive experiment.
LevelQVSQ × VSPQ × PVS × PVPQ × VPVS × VPP × VPC10.3090.2560.2720.2430.2650.2620.2590.2530.2580.266C20.2040.2570.2400.2700.2480.2510.2530.2600.2540.247R0.105−0.0010.032−0.0270.0170.0110.006−0.0070.0040.019
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