井敏1， 曲德鑫1， 唐泽阳1， 王昌东2， 张德金2， 乔振兴2， 孙静2， 盖国胜3
1. 山东建筑大学 材料科学与工程学院， 山东 济南 250101； 2. 山东鲁银新材料科技有限公司， 山东 济南 271104；3. 清华大学无锡应用技术研究院粉体工程中心， 江苏 无锡 214072
引用格式：
井敏，曲德鑫，唐泽阳，等. 铁基合金粉末表面卫星粉去除及其对激光熔覆的影响［J］. 中国粉体技术， 2026， 32（4）： 1-9.
Jing Min， Qu Dexin， Tang Zeyang， et al. Removal of satellite powder on surface of iron-based alloy powder and its effect on laser cladding［J］. China Powder Science and Technology， 2026， 32（4）： 1-9.
DOI：10.13732/j.issn.1008-5548.2026.04.006
收稿日期：2025-12-05，修回日期：2026-05-15，上线日期：2026-5-28。
基金项目：重点新材料研发及应用国家科技重大专项，编号：2025ZD0619900。
第一作者：井敏（1979—），女，副教授，博士，硕士生导师，研究方向为微纳米粉体整形包覆复合。E-mail：shandajingm@163.com。
摘要：【目的】针对铁基合金粉末表面存在卫星粉的问题，探究去除卫星粉的最佳工艺以及去除卫星粉后对粉末物化性质及激光熔覆层性能的影响机制。【方法】采用粉末整形机处理表面有卫星粉的铁基合金粉末，在氮气保护下设置不同转速和时间组合，利用扫描电镜、X射线衍射仪、激光粒度分析仪等表征粉末的形貌、结构和性质，获得最佳的整形工艺；将最佳整形工艺处理前、后的粉末在45钢表面进行激光熔覆，通过金相显微镜、显微硬度计、电化学工作站对比分析熔覆涂层的形貌、硬度和抗电化学腐蚀能力。【结果】一定的整形处理工艺能有效去除粉末表面的卫星粉，颗粒的球形度变好，松装密度、振实密度和流动性显著提高，且物相结构未发生改变、氧含量符合要求；采用去除卫星粉后的铁基合金粉末制备的激光熔覆涂层表面更平整，熔覆层厚度增加，显微硬度更高，自腐蚀电位更高，自腐蚀电流密度更小，表现出更优异的电化学腐蚀性能。【结论】铁基合金粉末颗粒去除卫星粉后，粉体自身性质的优化能够带来激光熔覆涂层的性能的提升。
关键词：激光熔覆；铁基合金粉；气雾化制粉；卫星粉；颗粒整形
Abstract
Objective To address the problem that satellite powder on the surface of gas-atomized iron-based alloy powder leads to a decrease in its flowability and apparent density， which in turn affects the quality of laser cladding layers， this study investigates an effective shaping process for removing satellite powder， and explores the influence mechanisms of satellite powder removal on the physicochemical properties of the powder and the performance of laser cladding layers.
Methods A powder shaping machine was used to treat the iron-based alloy powder with satellite powder on its surface. First， the effects of treatment under air and nitrogen atmospheres on the oxygen content of the powder were compared to determine the protective atmosphere. Subsequently， under a nitrogen atmosphere， different combinations of rotational speeds （3 000， 4 000， 5 000 r/min） and time （10， 20， 30 min） were set to perform shaping treatment on the powder. Scanning electron microscopy （SEM）， X-ray diffraction （XRD）， laser particle size analyzer， and other instruments were used to characterize the morphology， phase structure， apparent density， and flowability of the powder before and after treatment， so as to determine the optimal satellite powder removal process. The powder before and after treatment under the optimal process was used to prepare cladding layers on the surface of 45 steel by coaxial powder feeding laser cladding technology. Metallographic microscopy， a microhardness tester， and an electrochemical workstation were used to compare and analyze the cross-sectional morphology， microhardness， and electrochemical corrosion resistance of the cladding layers prepared from different powders.
Results and Discussion Oxygen content analysis showed that the nitrogen protective atmosphere could effectively control the oxygen increase of the powder. After 30 minutes of treatment， the oxygen mass fraction was close to that of the original powder， meeting the oxygen content requirements for laser cladding powder. XRD analysis showed that none of the treatment processes changed the Fe-Cr-Ni solid solution phase structure of the powder. SEM image analysis revealed that after treatment at rotational speeds of 4 000 r/min and 5 000 r/min for 20 minutes， the satellite powder on the particle surface was effectively removed or flattened， and the particle sphericity was significantly improved. Correspondingly， the apparent density of the powder increased to a maximum of 4.39 g/cm3， and the flowability was also significantly improved. Laser cladding experiments showed that the cladding layer prepared from the powder after satellite powder removal exhibited a smoother surface morphology， greater thickness， higher microhardness， higher self-corrosion potential， and lower self-corrosion current density， demonstrating superior electrochemical corrosion resistance.
Conclusion Under a nitrogen atmosphere， the shaping process with rotational speeds of 4 000 r/min and 5 000 r/min for 20 minutes can effectively remove satellite powder from the surface of iron-based alloy powder. It significantly improves the flowability， apparent density， and sphericity of the powder， without changing the phase structure. The optimization of powder properties leads to more uniform powder feeding and a more stable molten pool during laser cladding， thereby obtaining a cladding layer that is denser， thicker， harder， and has stronger corrosion resistance. This study provides an effective technical approach for improving the quality of iron-based alloy powder for laser cladding and the comprehensive performance of the cladding layer.
Keywords： laser cladding； iron-based alloy powder； gas-atomized powder； satellite powder； particle shaping
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