Development of thermo-mechanical simulation of WC/Inconel 625 metal matrix composites laser cladding and optimization of process parameters

Abstract

Laser cladding (LC) of industrial parts with tungsten carbide (WC)/Inconel 625 composite is highly regarded for its unique properties, for applications such as repair and improvement of surface and mechanical properties. In order to achieve high quality cladding, with minimal impact on the metallurgical structure and minimal stress and distortion caused by high local heating and cooling rate, it is necessary to determine the important parameters of the process, evaluate and investigate the effect of each one. Today, the numerical solution of this process can help predict, understand and evaluate the characteristics of the LC, and control and optimize it. In this research, using the thermo-elastoplastic simulation of the WC/Inconel 625 composite cladding process using finite element method (FEM) and the arbitrary Lagrangian-Eulerian (ALE) solution method with moving mesh strategy, the properties of the created coating have been evaluated. The laser is modeled with a moving Goldak double ellipsoidal heat source and the physical and mechanical properties of the temperature-dependent materials are considered. The physical and mechanical properties of the composite were extracted from the role of mixture and Ashby's method, respectively. Using Taguchi's experimental design method, the effect of important process parameters on output parameters such as dilution, cladding geometry, heat and stress have been investigated. Finally, the optimal parameters as well as the relationship between the parameters and each characteristic have been obtained using the linear regression model.