Determining formation features of a wear-resistant layer surfaced with powder tape

This study investigates the technological process of surfacing parts with a powder tape. The task addressed is to optimize the technological process of multilayer arc surfacing with powder tapes based on mathematical modeling of the formation of a seam of a given chemical composition with a minimum allowance for subsequent mechanical processing. The technological parameters for the coating formation process have been calculated depending on the thickness of the surfacing layer of surfaces after machining, the maximum number of surfacing layers, and the required chemical composition of the weld metal. That has made it possible to devise technological recommendations for surfacing complex alloys on parts of a wide range of applications that operate under conditions of intensive wear. The results are relevant in additive technologies, part of which is arc surfacing with powder electrodes of various designs, when it is necessary to fabricate an article by sequentially applying layers along a trajectory that repeats the geometry of the parts. The proposed mathematical models make it possible to obtain a reliable and operational assessment of the influence of technological process parameters on the formation of the chemical composition and geometry of the deposited layer during multilayer surfacing, taking into account the minimum waste of deposited metal after finishing grooving. With values of the ratio of the height of the reinforcement roller to its width (≤ 0.3) and the relative surfacing step within 0.75–0.90, the maximum efficiency of the formation of a multilayer coating is ensured (by the minimum height of the deposited layer). It also enables the minimization of costs for subsequent machining, taking into account the imitation of errors (by the maximum height of irregularities). If the weld reinforcement coefficient is more than 2, then the required chemical composition is achieved already in the second coating layer. The resulting numerical accuracy makes it possible to predict effective ways to save welding materials and reduce the labor intensity of the process when surfacing complex-alloyed wear-resistant alloys.