Development of a Theoretical Process Map for Laser Cladding Using a Three-Dimensional Conduction Heat Transfer Model

Abstract

In this article, a three-dimensional conduction heat transfer model is developed to predict the clad geometry (e.g., height, width, and dilution) and microstructure (scale and morphology) of the solidified layer for a laser cladding process. The effect of controllable input process parameters like absorbed laser power, powder deposition rate, and processing speed on the clad characteristics is critically assessed with the help of dimensionless parameters. A process map is developed which enables operators to pick up the proper process parameters for a feasible laser cladding process with desirable characteristics. The present conduction model is solved using the finite-volume method in a multiblock, nonorthogonal grid system. The effect of melt pool convection is taken care of by introducing an enhanced thermal conductivity factor for the molten pool.