Paint Removal Performance and Sub-Surface Microstructural Evolution of Ti6Al4V Alloy Using Different Process Parameters of Continuous Laser Cleaning

Laser cleaning technology has been increasingly applied in the removal of damaged protective coatings from aircraft components due to its environmental friendliness and high efficiency. Appropriate laser cleaning process parameters improve cleaning efficiency while preventing substrate damage. In this study, a Gaussian continuous-wave laser was used to remove the 120 μm coating on the surface of Ti6Al4V alloy. The influence of laser power (100 W to 200 W) and scanning speed (520 mm/min to 610 mm/min) on the paint removal effect was explored based on paint removal rate, surface roughness, microstructural evolution, and the hardness’ change in the direction of heat transfer. The results reveal that optimal paint removal parameters are achieved at a laser power of 100 W with a scanning speed of 550 mm/min. The surface roughness of the sample after paint removal (55 nm) is similar to that of the original substrate (56 nm). Through EBSD analysis, the influence of laser thermal accumulation on the microstructure of the substrate is relatively small. The average hardness of the cross-section after cleaning was 347 HV, which was only 3.41% higher than that of the original substrate. This confirms that parameter-controlled laser cleaning can effectively remove ~120 μm thick paint layers without inflicting damage on the substrate.