Multi-track alternated overlapping model suitable for variable laser cladding process parameters

Abstract

The surface flatness of the coating prepared by laser cladding (LC) is determined by the overlapping distance, which significantly affects its quality and the machining allowance for subsequent subtractive manufacturing. In this study, the multi-track overlapping model was established based on the alternate overlapping build-up strategy, and simplified by appropriately truncating the Taylor series expansion. Meanwhile, it was combined with response surface method (RSM) to establish the mapping relationship between process parameters (laser power, scanning speed and powder feeding rate) and the optimal overlapping distance. The results show that the mean of multi-track overlapping error of the model was 8.1%, and there were no cracks and gaps in the coating. The proposed overlapping model can effectively find the optimal overlapping distance under different process parameters of LC, which provides an important theoretical basis for efficient surface strengthening or repair of engineering parts. • The multi-track overlapping model was established based on the alternate build-up strategy. • The model was simplified by appropriately truncating the Taylor series expansion. • The overlapping distance was predicted by Response surface method. • The microstructure and microhardness of multi-track Inconel718 coating were investigated.