Abstract
Laser cladding on curved surfaces is essential in industrial applications for restoration and remanufacturing of high-value parts. This study investigated the influence of different factors on clad width, clad height, and dilution rate in curved surface laser cladding with curved path. Mathematical models were developed using central composite designs to predict these geometric characteristics by controlling laser power, scanning speed, gas flow, and altering the outside radius of the cylindrical substrate. Analysis of variance and response surface methodology indicated that clad width increased with increasing laser power and reducing scanning speed. Clad height positively correlated to laser power and negatively correlated to the outside radius of the cylindrical substrate. Increasing the laser power while decreasing the scanning speed led to an increase in dilution rate. Afterwards, the geometric characteristics of the clad were improved by optimizing these factors with the target to maximize clad width and height as well as to minimize dilution rate. The difference between model predictions and experimental validations for clad width, clad height, and dilution rate were 3.485%, 3.863%, and 6.566%, respectively. The predicted accuracy was verified with these models, and they were able to provide theoretical guidance to predict and control the geometric characteristics of curved surface laser cladding with a curved path.
Highlights
Laser cladding is an advanced surface modification technology that was introduced in 1980s for producing metallurgical bond coating
The predicted accuracy was verified with these models, and they were able to provide theoretical guidance to predict and control the geometric characteristics of curved surface laser cladding with a curved path
All of the determination coefficients (R-square, adjusted R-square, and predicted R-square) were close to 1. These results demonstrate the remarkable fitting accuracy of this regression model
Summary
Laser cladding is an advanced surface modification technology that was introduced in 1980s for producing metallurgical bond coating. Because of the high energy density during the process, coatings are deposited with precise dimensions and a high production efficiency with minor heat-affected zones, low dilution rates, and outstanding metallurgical bonding. This technology has been widely used in remanufacturing and restoration of important high-value parts [3,4,5,6]. Yu et al applied Taguchi and grey relational analysis methods to study the relationship between similar processing parameters (laser power, scanning speed, and powder feeding rate) and the responses (clad width, clad height, and dilution rate).
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