Thermo-mechanical modelling to evaluate residual stress and material compatibility of laser cladding process depositing similar and dissimilar material on Ti6Al4V alloy

Abstract

• 3D finite element modelling of laser cladding process has been developed to predict residual stress at clad, substrate and interface. • Effect of Similar and dissimilar materials on the development of residual stress during laser cladding. • Benchmarking the model with experimental results. • Laser materials interaction of alloy and ceramic materials, and their effect on generation of residual stress. • Use of commercial software for any material system to select appropriate clad materials with minimised residual stress. The formation of residual stresses due to thermo-mechanical effect and microstructural transformation in the Laser Cladding process predominantly affects the final product integrity and service life. A 3D finite element transient thermo-mechanical model has been developed to predict thermal profile and residual stress distribution for repair application of Ti6Al4V alloy using a moving heat source. Then the developed model was applied for the deposition of ceramic materials Al 2 O 3 and TiC on Ti6Al4V alloy substrate. The outcome of this model is to predict temperature distribution, cooling rate, melt pool depth, heat affected zone and residual stress. This study mainly highlights the thermal effect on the residual stresses for similar and dissimilar clad/substrate materials and suggests the suitable cladding material with minimum residual stress.