Abstract
This paper investigated the correlation between the processing parameters and the properties of clad deposited by laser cladding on a curved surface. Mathematical models relating the processing parameters (laser power, scanning speed, gas flow, and overlap ratio) and clad properties (flatness ratio and pore area) were established by central composite design. Analysis of variance and experimental validation confirmed the validity of the models. The results indicated that the flatness ratio was negatively influenced by the larger scanning speed, gas flow, and overlap ratio, while the pore area was enlarged by the increasing of scanning speed, and increasing the overlap ratio lead to the pore area reducing at first and then increasing. Optimized processing parameters were obtained under the target of maximizing the flatness ratio and minimizing the pore area. The developed mathematical models enabled predicting the flatness ratio and pore area with optimized processing parameters. The validation experimental result verified the prediction accuracy of the models and displayed target improvement compared with the original central composite design. The results provide theoretical guidance in multi-track laser cladding on a curved surface for the prediction and control of the geometric characteristics of the coating and the optimization of the processing parameters. This research outcome provides guidance for the coating deposition application in crankshaft surface coating or surface restoration, rotary parts coating deposition, or complex shape tool manufacturing. It also forms the fundamental basis for the extensive application of multi-track laser cladding on curved substrates in the additive manufacturing industry.
Highlights
Laser cladding utilizes a high-energy laser beam to irradiate the cladding material and substrate, causing rapid melting and solidification in the cladding zone
This study applied central composite design in response surface methodology, studied the influence of laser power, scanning speed, gas flow, and overlap ratio on the clad properties, established mathematical models relating processing parameters and clad properties, and achieved the prediction and control of multi-track laser cladding on a curved surface
During the laser cladding on a curved surface, the overlap ratio implied the most significant impact on the flatness ratio
Summary
Laser cladding utilizes a high-energy laser beam to irradiate the cladding material and substrate, causing rapid melting and solidification in the cladding zone. Utilized regression analysis and discussed the correlations between main processing parameters (laser power, scanning speed, powder feeding rate) and geometrical characteristics (clad width, height, penetration depth, dilution, and wetting angle) in single-track laser cladding. In the application of response surface methodology, Farahmand et al used central composite design and response surface methodology to study the influence of laser power, powder feeding rate, and scanning speed on the clad height, heat-affected zone depth, and microhardness of the cladding layer. This study applied central composite design in response surface methodology, studied the influence of laser power, scanning speed, gas flow, and overlap ratio on the clad properties, established mathematical models relating processing parameters and clad properties, and achieved the prediction and control of multi-track laser cladding on a curved surface
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