Abstract
As an essentially multi-input multi-output process, determination of optimal conditions for laser cladding normally requires multi-objective optimization. To understand multi-response coupling, the effects of processing parameters on the morphology quality of multi-pass laser claddings of Fe50/TiC on medium carbon steel AISI 1045 were investigated based on composite central design using response surface methodology. Multiple responses, including clad width, flatness, and non-fusion area, were transformed into a single objective through grey relational analysis, with weights objectively identified by principal component analysis. The correlation between grey relational grade (GRG) and process parameters was established by regression analysis. The results show that the GRG response model has excellent goodness of fit and predictive performance. A validation experiment was conducted at the process condition optimized for maximum GRG. The relative error of the predicted optimal GRG is 4.87% whereas those of interested individual objectives, i.e. clad width, flatness, and non-fusion area, are 5.73%, 2.97%, and 6.73%, respectively, which verifies the accuracy of the established model. The investigation of mechanical properties suggests the hardness of substrate can be improved from 20 HRC to 60 HRC and wear resistance to over 8.14 times better.
Highlights
Laser cladding is a widely used surface engineering technology which applies high density laser energy to the substrate with additive powder to rapidly obtain metallurgical bonding and significantly improve mechanical, physical, and chemical properties of the substrate surface, such as wear, corrosion, and oxidization resistance [1,2]
Due to its low dilution, small distortion, and better surface quality compared with conventional processes, laser cladding technology has been implemented in numerous fields like metallurgical mining, energy transportation, machinery manufacturing, and aerospace [3,4]
The maximum signal-to-noise ratio (SNR) values were obtained at the 26th, 7th, and 28th experimental runs for the three responses
Summary
Laser cladding is a widely used surface engineering technology which applies high density laser energy to the substrate with additive powder to rapidly obtain metallurgical bonding and significantly improve mechanical, physical, and chemical properties of the substrate surface, such as wear, corrosion, and oxidization resistance [1,2]. Mondal et al [11] prepared Ni/Cr/Mo composite coatings on AISI 1040 steel with a L9 orthogonal array, using GRA (response target weight was one-third) to build the relationship between process parameters (laser power, scan speed, and powder feed rate) and clad quality characteristics (clad height and width) to produce the best geometrical morphology. Zhang and Kovacevic [12] developed AISI 420/VC composite coatings on an A36 surface with L9 orthogonal array, applying the grey relational method (contribution one-third) to optimize processing parameters (laser power, scanning speed, and powder feed rate) considering multiple characteristics related to wear resistance (clad height, carbide volume fraction, and Fe matrix hardness). The established regression model was validated with an experiment of optimized process condition
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