Prediction of the bead profile for wide-band laser cladding via hybrid model of mathematics and thermal simulation

Abstract

Wide-band laser cladding has high deposition rate and low dilution due to the large laser spot and rectangular powder nozzle. A mathematical model was proposed to predict the track cross-section profile for wide-band laser cladding. The melt pool morphology and powder spatial concentration were taken into consideration to improve the accuracy of the model. Thermal field simulation was carried out to study the melt pool evaluation with process parameters, while infrared images were used to verify the simulation fidelity. Powder stream photographs were taken via a CCD (charge coupled device) camera to obtain the powder spot size. Single and multi-track cladding experiments were conducted, and calculated contours of the model coincide well with the experimental results. Simulated and measured melt pool width and length agree with in 2.16% and 2.36% of error, respectively. The error of predicted cross section area is less than 9.35%. The model also has good ability to predict the powder efficiency and morphology of the cladding layer.