Key Takeaways & Executive Findings
- •• • Vertical cross texture achieved a wear rate of 2.33%, an 80% reduction compared to ordinary uncoated blades, directly extending service life and reducing replacement downtime in agricultural operations. • • Cladding powder consumption dropped to 4.1 g per blade versus 18.6 g for traditional overlapping cladding, a 67% reduction, yielding substantial cost savings in high-volume blade production. • • Wear resistance coefficients for vertical and parallel textures were 3.31 and 4.55 times that of untextured blades, respectively, demonstrating that texture geometry critically influences tribological performance under soil abrasion. • • Laser confocal microscopy revealed the vertical cross texture had a wear area of 852.559 μm², only 18% of the perpendicular texture's wear area, confirming that cross-hatched grooves better retain self-filling soil and distribute contact stresses.
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Abstract
Rotary tiller blades suffer continuous abrasive wear from soil, sand, and crop residues, causing premature failure and high replacement costs. Conventional overlapping laser cladding consumes excessive powder and generates interfacial defects. This study designed and fabricated four non-overlapping textured Ni60A-WC (20%) composite coatings with grooves on 245-type 65Mn steel blades: perpendicular to blade edge, parallel to blade edge, vertical cross (90° intersection), and oblique cross (45° intersection). Grooves enable soil self-filling to form a protective layer. Discrete element method (EDEM) simulations identified stress concentration at the forward cutting edge, side cutting edge, and their junction. Field tests compared textured, untextured, and ordinary blades. The vertical cross texture exhibited the best wear resistance, with a wear rate of only 2.33%, an 80% reduction versus ordinary blades, while reducing cladding powder consumption by 67% (4.1 g vs. 18.6 g for traditional overlapping). Wear data correlated with simulated cumulative contact force. Laser confocal microscopy showed the wear area of the vertical cross texture (852.559 μm²) was only 18% of that of the perpendicular texture. The wear mechanism involves soil and sand filling the grooves to form a soft-hard alternating self-filling wear-resistant coating parallel to the cutting direction, enabling a fill-wear-refill dynamic cycle. This approach reduces powder usage while enhancing wear resistance.
1. Introduction
Rotary tiller blades in agricultural machinery endure severe abrasive wear from soil, sand, and crop residues, leading to frequent replacement and escalated operational costs. Traditional laser cladding with overlapping tracks mitigates wear but consumes excessive Ni60A-WC powder and introduces interfacial defects such as pores and cracks, undermining both cost-effectiveness and long-term reliability. The industry requires a coating strategy that reduces material consumption without compromising wear resistance.
This study addresses the bottleneck by designing non-overlapping textured Ni60A-WC (20%) composite coatings with engineered grooves on 245-type 65Mn steel blades. Four groove configurations—perpendicular, parallel, vertical cross, and oblique cross—were evaluated. The grooves facilitate soil self-filling, creating a dynamic soft-hard alternating protective layer that replenishes during operation. EDEM simulations pinpointed stress concentrations at the forward and side cutting edges, guiding reinforcement. Field tests and laser confocal microscopy quantified wear rates and mechanisms, establishing a pathway to lower powder usage and enhanced blade durability.
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ZHU Chen, JIANG Fulin, XIONG Jiajun, YANG Fazhan, LI Yuhuan (2026). Design and Field Testing of Laser Cladding Coatings with Surface Textures on Rotary Tiller Blades. Surface Technology (表面技术). https://doi.org/10.16490/j.cnki.issn.1001-3660.2026.11.009
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Frequently Asked Questions
What is the primary wear mechanism of the textured composite coatings under field conditions?
Soil and sand particles fill the grooves, forming a soft-hard alternating self-filling layer parallel to the cutting direction. The soft units (soil) and hard units (coating) share the wear load, and the soft units are continuously replenished, enabling a fill-wear-refill dynamic cycle that reduces direct abrasive contact on the coating.
How does the vertical cross texture compare to the perpendicular texture in terms of wear area?
Laser confocal microscopy showed the vertical cross texture had a wear area of 852.559 μm², which is only 18% of the wear area observed for the perpendicular texture, indicating significantly better wear resistance.
What is the economic advantage of the non-overlapping textured coating over traditional overlapping cladding?
The vertical cross texture required only 4.1 g of Ni60A-WC (20%) powder per blade, compared to 18.6 g for traditional overlapping cladding, achieving a 67% reduction in powder consumption while improving wear resistance.
How do the wear resistance coefficients of textured blades compare to untextured blades?
The wear resistance coefficients for vertical and parallel textured blades were 3.31 and 4.55 times that of untextured blades, respectively, demonstrating a substantial improvement in durability.
What role did EDEM simulation play in optimizing the coating design?
EDEM simulation identified the forward cutting edge, side cutting edge, and their junction as stress concentration zones prone to wear. Field tests confirmed these as primary wear locations, guiding the placement of textured coatings to reinforce critical areas.
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