Optimized Laser Processing Parameters Research Articles

Micro-cracks generation and growth manipulation by all-laser processing for low kerf-loss and high surface quality SiC slicing

Low kerf-loss and high surface quality silicon carbide (SiC) wafer slicing is key to reducing cost, improving productivity, and extending industrial applications. In this paper, a novel all-laser processing approach is proposed by combining laser micro-cracks generation and growth manipulation. The first high fluence pulsed laser is applied to generate micro-cracks inside SiC, which increases its laser energy absorption. The second low fluence pulsed laser achieves the manipulation of micro-cracks growth and interconnection to separate SiC wafer. The optimal laser processing parameters are obtained to separate a 4H-SiC substrate at a thickness of 500 µm. The sliced surface is clean with average surface roughness (Sa) of 186 nm, standard deviation of 0.037, and kerf-loss of 915 nm. This laser slicing approach can be applied for high-hardness transparent material separation.

Near-full density enabled excellent dynamic mechanical behavior in additively manufactured 316L stainless steels

Mechanical properties of additively manufactured alloys are momentously affected by the fabrication defects, thus limiting their applications in extreme conditions. Here we report on a near fully dense 316L stainless steel via optimized laser processing parameters. The results reveal that the dynamic mechanical response exhibits much greater sensitivity to defects than the quasi-static one. The densest specimen (porosity < 0.01 %, 260W-316L) exhibits superior spall strength of 3.87 GPa and negligible damage fraction of 0.03 % at peak stress of 4.8 GPa, which are 12 % higher and 92 % smaller than those of 0.18 % porosity specimen (300W-316L). For both horizontal and vertical impacts, hardly any anisotropy of spall strength is observed in 260W-316L, demonstrating the crucial role of the pore defects on the dynamical behavior. Moreover, dislocation slip dominated spallation mechanisms have been observed in the additively manufactured 316L specimens, accompanied by a small amount of deformation twinning and martensitic transitions. This comprehensive understanding of the defect-dependent spallation behavior and deformation mechanisms provides valuable insights for optimizing the dynamic mechanical properties of additively manufactured metals and alloys.

Prediction of Femtosecond Laser Etching Parameters Based on a Backpropagation Neural Network with Grey Wolf Optimization Algorithm.

Investigating the optimal laser processing parameters for industrial purposes can be time-consuming. Moreover, an exact analytic model for this purpose has not yet been developed due to the complex mechanisms of laser processing. The main goal of this study was the development of a backpropagation neural network (BPNN) with a grey wolf optimization (GWO) algorithm for the quick and accurate prediction of multi-input laser etching parameters (energy, scanning velocity, and number of exposures) and multioutput surface characteristics (depth and width), as well as to assist engineers by reducing the time and energy require for the optimization process. The Keras application programming interface (API) Python library was used to develop a GWO-BPNN model for predictions of laser etching parameters. The experimental data were obtained by adopting a 30 W laser source. The GWO-BPNN model was trained and validated on experimental data including the laser processing parameters and the etching characterization results. The R2 score, mean absolute error (MAE), and mean squared error (MSE) were examined to evaluate the prediction precision of the model. The results showed that the GWO-BPNN model exhibited excellent accuracy in predicting all properties, with an R2 value higher than 0.90.

Controlled photothermal ablative processing of commercial polymers minimizing undesired thermal effects under high frequency femtosecond laser irradiation

The response of three commercial polymers (poly(vinyl chloride) (PVC), poly(ethylene terephthalate) (PET) and polypropylene (PP)) with different thermal properties under high repetition rates (1 kHz-1 MHz) with femtosecond (450 fs) multi-pulse laser irradiation at λ = 515 nm (1.4 J/cm2) is reported resulting in a complete study with controlling the ablation depth and minimizing collateral thermal effects. Tunable ablation depth is achieved accurately by varying the repetition rate at a constant fluence. The results are compared to a photothermal model that aims at explaining the heat accumulation effect of successive pulses as a function of the repetition rate and predicts three different heat regimes (non-cumulative, cumulative and saturation). The threshold frequencies for each regime can be estimated from the model, providing control for selecting frequency values and thermal regimes. Thermal analyses are performed to characterize the materials, concluding that thermal parameters are vital for selecting optimal materials and laser processing parameters.

Additive manufacturing of Fe-6.5 wt.%Si transformer steel toroidal cores: Process optimization, design aspects, and performance

Fe-Si electrical steels are conventionally popular materials for transformer application. Although higher Si (4wt.%<) content is favorable for increasing the resistivity and improving the soft magnetic properties, fabrication of transformer core with higher Si containing electrical steels is difficult by conventional wrought processes due to an increase in its brittleness. Additive manufacturing provides a novel alternative plausible way to fabricate transformer cores with higher Si content and unique design features. The current work focused on process optimization and design aspects of laser powder bed fusion additive manufacturing of Fe-6.5wt.% electrical steel. Additively manufactured components with 99.5% relative density were produced. The optimally fabricated component contained columnar grains of α-FeSi phase morphologically oriented in the build direction. The optimally fabricated Fe-6.5wt.% component was also subjected to annealing treatment at 1150∘C for 1 h in Ar resulting in multi-fold grain growth and improved soft magnetic response. Based on optimal laser processing parameters, 3 different designs for toroidal cores with slit patterns for varying degree of cross-sectional areas were additively fabricated. The toroidal cores were subjected to same annealing treatment as that of the additively fabricated component. Core with least cross-sectional area exhibited improved magnetic performance compared to the other designs.

Parameters optimization for laser-cladding CoCrFeNiMn high-entropy alloy layer based on GRNN and NSGA-II

In order to improve the bonding strength of FeCoCrNiMn cladding layer, laser power, scanning speed and powder feeding rate were selected as the optimization variables; the aspect ratio, dilution rate and heat affected zone depth of the cladding layer were selected as the optimization indicators; a three-factor three-level full-factor experiment was designed; a nonlinear model of cladding parameters and cladding performance was established by generalized regression neural network algorithm (GRNN), while the error of prediction value and experimental results was less than 10%. A set of optimal Pareto frontiers were obtained by the Non-Dominance Ordering Genetic Algorithm (NSGA-II), and the optimal individuals were obtained based on the equal weights, and the optimal cladding parameters were as follows: laser power 2.33 kW, scanning speed 2.90 m/min, and powder feeding rate 12.46 g/min. The cladding layer prepared under the optimal parameters has a dense cross-section with no defects such as cracks and porosity. The joint optimization using the GRNN neural network and the NSGA-II genetic algorithm can obtain excellent results, and the relative error between the experimental and predicted values can be controlled within 10%. The application of optimized laser process parameters can significantly improve defects such as poor adhesion, cracks and porosity on the surface of the cladding layer, and also improve the surface hardness and wear resistance. The experimental results show that the wear rate of the cladding layer prepared by the optimized parameters is 3.21×10−5 mm3/N·m, which is 1.5 times higher than that of the cladding layer prepared by P=2.1 kW, V=3 m/min and C=9 g/min. The wear mechanism mainly includes abrasive wear, plastic deformation and oxidative wear.

Investigation of electromagnetic wave absorption and anti-corrosion mechanism of multifunctional Ni/AlN composite coatings with core-shell structure by laser cladding

Developing efficient microwave absorbing materials (MAMs) suitable for prolonged use in marine environments is of great importance. Laser cladding serves as one of the new techniques for the material of surface modification and microwave-absorbing materials in the 3D printing. However, it is usually challenging to prepare materials that combine desirable printability, corrosion resistance, and microwave absorption properties using this technology. To enhance the microwave absorption of laser-clad Ni-based alloys, the method of impedance modulation was employed by incorporating ceramic powders with varying AlN content. The results show that Ni/AlN/MWCNTs composite functional materials with core-shell heterostructures were prepared under optimized laser processing parameters. This unique core-shell structure optimizes impedance matching increased polarization loss and multiple scattering to boost microwave absorption. The optimized 20wt% AlN content resulted in a minimum RL of -13.24dB at 13.86GHz, in addition, electrochemical tests showed that AlN enhanced the resistance to the corrosion medium transfer during the corrosion process, and the corrosion resistance of the Ni/AlN/MWCNTs composites material (self-corrosion current density (8.52 × 10-8), the charge transfer resistance (1.55 × 10-5)). Therefore, this work provides innovative theoretical and practical insight for the design and manufacture of advanced microwave-absorbing materials for harsh environments by laser melting technology.

Gradient-Pattern Micro-Grooved Wicks Fabricated by the Ultraviolet Nanosecond Laser Method and Their Enhanced Capillary Performance.

Capillary-gradient wicks can achieve fast or directional liquid transport, but they face fabrication challenges by traditional methods in terms of precise patterns. Laser processing is a potential solution due to its high pattern accuracy, but there are a few studies on laser-processed capillary-gradient wicks. In this paper, capillary step-gradient micro-grooved wicks (CSMWs) were fabricated by an ultraviolet nanosecond pulsed laser, and their capillary performance was studied experimentally. The CSMWs could be divided into three regions with a decreasing capillary radius. The equilibrium rising height of the CSMWs was enhanced by 124% compared to the non-gradient parallel wick. Different from the classical Lucas-Washburn model describing a uniform non-gradient wick, secondary capillary acceleration was observed in the negative gradient direction of the CSMWs. With the increase in laser power and the decrease in scanning speed, the capillary performance was promoted, and the optimal laser processing parameters were 4 W-10 mm/s. The laser-enhanced capillary performance was attributed to the improved hydrophilicity and reduced capillary radius, which resulted from the increased surface roughness, protrusion morphology, and deep-narrow V-shaped grooves induced by the high energy density of the laser. Our study demonstrates that ultraviolet pulsed laser processing is a highly efficient and low-cost method for fabricating high-performance capillary gradient wicks.

Laser-Based Directed Energy Deposition of Ceramic Nanoadditivated AA7075 Powder Alloys

AA7075 is one of the most resistant aluminium alloys, so it is frequently used in very demanding industries as aeronautics or defence. However, the 7075 alloy falls into the non-weldable category thus hardly processable through additive manufacturing processes, and specially on laser-based DED (Directed Energy Deposition). The low absorption together with cracking behaviour remain a challenge for the industrialisation of these processes. Alloying with minor elements or addition of nano-reinforcement have been proven as a successful approach to increase its manufacturability. In this work, the feasibility of printing 7075 with nano-TiC as additive was evaluated. Two compositions with 0.5 and 2% in weight were developed by dry mixing. The powders were characterized by scanning electron microscopy (SEM) and flowability was compared with the unreinforced alloy. With the optimal laser process parameters, 3D coupons were printed to be characterized microstructurally, thermally, and mechanically. Process monitoring using thermal and high-speed cameras was carried out to gain insight into the thermal behaviour of the melt-pool and resulting process stability. After printing, aspect ratio of single tracks was measured, and dilution was also evaluated. Although addition of 0.5% of n-TiC promotes a slight improvement on the alloy, allowing it to be mechanically tested, it still presents some defects as porosity. By increasing the content up to 2%, both the quality and the mechanical performance were enhanced significantly.

Ultrafast-Laser-Induced Tailoring of Crystal-in-Glass Waveguides by Precision Partial Remelting

Space-selective laser-induced crystallization of glass enables direct femtosecond laser writing of crystal-in-glass channel waveguides having nearly single-crystal structure and consisting of functional phases with favorable nonlinear optical or electrooptical properties. They are regarded as promising components for novel integrated optical circuits. However, femtosecond-laser-written continuous crystalline tracks typically have an asymmetric and strongly elongated cross-section, which causes a multimode character of light guiding and substantial coupling losses. Here, we investigated the conditions of partial remelting of laser-written LaBGeO5 crystalline tracks in lanthanum borogermanate glass by the same femtosecond laser beam which had been used for their writing. Exposure to femtosecond laser pulses at 200 kHz repetition rate provided cumulative heating of the sample in the vicinity of the beam waist sufficient to provide space-selective melting of crystalline LaBGeO5. To form a smoother temperature field, the beam waist was moved along the helical or flat sinusoidal path along the track. The sinusoidal path was shown to be favorable for tailoring the improved cross-section of the crystalline lines by partial remelting. At optimized laser processing parameters, most of the track was vitrified, and the residual part of the crystalline cross-section had an aspect ratio of about 1:1. Thermal-induced stress emerging during the tailoring procedure was efficiently eliminated by fine post-annealing. The proposed technique suggests a new way to control the morphology of laser-written crystal-in-glass waveguides by tailoring their cross-section, which is expected to improve the mode structure of the guided light.

Experimental study on laser polishing additive manufacturing Ti6Al4V

As a new precision processing technology, laser polishing is widely used in metal and non-metal. Laser polishing technology is especially suitable for parts with high hardness and small size. In this paper, a full factor experimental were carried out to investigate the effect of continues wave laser with a wavelength of 1064nm on the surface quality of additive manufacturing Ti6Al4V. The experimental result shows that a smooth surface can be obtained and the average roughness is reduced from 14.95μm to 1.756μm with the reduction rate is as high as 88.3% when laser power is 170W and scan speed is 60mm/s. And the height of the peaks and valleys on the sample surface has also been greatly reduced in condition of the optimized laser processing parameters.

Moisture-resistant, stretchable NOx gas sensors based on laser-induced graphene for environmental monitoring and breath analysis

The accurate, continuous analysis of healthcare-relevant gases such as nitrogen oxides (NOx) in a humid environment remains elusive for low-cost, stretchable gas sensing devices. This study presents the design and demonstration of a moisture-resistant, stretchable NOx gas sensor based on laser-induced graphene (LIG). Sandwiched between a soft elastomeric substrate and a moisture-resistant semipermeable encapsulant, the LIG sensing and electrode layer is first optimized by tuning laser processing parameters such as power, image density, and defocus distance. The gas sensor, using a needlelike LIG prepared with optimal laser processing parameters, exhibits a large response of 4.18‰ ppm−1 to NO and 6.66‰ ppm−1 to NO2, an ultralow detection limit of 8.3 ppb to NO and 4.0 ppb to NO2, fast response/recovery, and excellent selectivity. The design of a stretchable serpentine structure in the LIG electrode and strain isolation from the stiff island allows the gas sensor to be stretched by 30%. Combined with a moisture-resistant property against a relative humidity of 90%, the reported gas sensor has further been demonstrated to monitor the personal local environment during different times of the day and analyze human breath samples to classify patients with respiratory diseases from healthy volunteers. Moisture-resistant, stretchable NOx gas sensors can expand the capability of wearable devices to detect biomarkers from humans and exposed environments for early disease diagnostics.

Effects of Y2O3 on the microstructure evolution and electromagnetic interference shielding mechanism of soft magnetic FeCoSiMoNiBCu alloys by laser cladding

Laser cladding is one of the new techniques for additive manufacturing of metal alloy-based electromagnetic shielding materials. However, it is generally difficult to prepare alloys with ideal printability, soft magnetism and electromagnetic interference (EMI) shielding effectiveness (SE) using this technique. To improve the electromagnetic shielding performance of laser cladded Fe-Co based soft magnetic alloys, a new FeCoSiMoNiBCu alloy was prepared by laser multilayer cladding using metal powders added with different content of Y 2 O 3 . The results show that the FeCoSiMoNiBCu alloys prepared under optimized laser processing parameters exhibit excellent soft magnetism and electromagnetic shielding properties. The microstructure of the prepared alloys is mainly composed of α (bcc) phase, Fe 2 B, YFe 10 Mo 2 and B 6 Co 21 Mo 2 phases. The Y 2 O 3 powder has played significant effects on the soft magnetism and electromagnetic shielding properties of the alloys. When added with 1.5 wt% Y 2 O 3 , the alloy samples exhibit the highest saturation magnetization (186.2 emu/g) together with a superior EMI shielding effectiveness of 95 dB at 23.5 GHz, which is a 25–58% improvement compared the alloy without adding Y 2 O 3 . The mechanisms for the improved EMI shielding performance of the laser cladded FeCoSiMoNiBCu alloys depend on a synergistic effect of enhanced dielectric loss and ohmic loss; specifically, the α-Fe mainly promotes the dielectric loss, while the ohmic loss is enhanced by a “fish-bone” shaped phase composed of α (bcc) phase, Fe 2 B, YFe 10 Mo 2 and B 6 Co 21 Mo 2 . This study provides a new theoretical and technical guidance for the development of high-performance EMI shielding alloys using laser cladding technique. • A new FeCoSiMoNiBCu alloy with excellent electromagnetic shielding effectiveness was successfully prepared by laser cladding. • The microstructure evolution mechanism of Y 2 O 3 promoted laser cladding FeCoSiMoNiBCu alloys was clarified. • The influence of the type, size and proportion of in-situ magnetic phases on the FeCoSiMoNiBCu alloy’s electromagnetic shielding interference model was established by the experiments and first-principles calculations. • The electromagnetic shielding interference effectiveness of the laser cladding new FeCoSiMoNiBCu alloy was improved about 25–58%.

Research on the Preparation Process and Performance of a Wear-Resistant and Corrosion-Resistant Coating

In order to study the wear resistance and corrosion resistance of a composite material with a Fe316L substrate and Co-Cr-WC coating, Co-Cr alloy coatings with different mass fractions of WC (hard tungsten carbide) were prepared on a Fe316L substrate by laser cladding technology. The phase composition, microstructure and element distribution were analyzed by X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The hardness of the samples was tested by a Vickers microhardness tester, the friction coefficient and wear amount of the samples were tested by a friction and wear tester, and the corrosion resistance of the samples was tested by an electrochemical corrosion workstation. The results showed that the macroscopic appearance of the coating surface was good without obvious cracks, and the microstructures were mostly equiaxed crystals, cellular crystals and dendrites. With the addition of WC, the structures near the particles became more refined and extended from the surface of the WC particles. When the WC content was 40%, defects such as fine cracks appeared in the coating. The average microhardness of the 30%WC-Co-Cr coating was 732.6 HV, which was 2.29 times that of the Fe316L matrix; the friction coefficient was 0.16, and the wear amount was 14.64 × 10−6 mm3 N−1 m−1, which were 42.1% and 44.47% of the matrix, respectively; the self-corrosion voltage of the cladding layer was 120 mV, and the self-corrosion current was 7.263 × 10−4 A/cm2, which were 30.3% and 7.62% of the substrate, respectively. The experimental results showed that the laser cladding Co-Cr-WC composite cladding layer could significantly improve the wear resistance and corrosion resistance of the Fe316L matrix under the optimal laser process parameters.

Fabrication and properties of micro-additive manufactured Ni-based composite coatings by short-pulsed laser

Laser micro-additive technology exhibits excellent promising applications in processing microelectronic components, fabricating medical implants and improving local properties of micro-devices. In this paper, laser micro-additive technology is utilized to fabricate Ni-based micro-cladding coatings by a short-pulsed laser with the pulse width of 10 ns and maximum power of 20 W, and the effect of laser process parameters on micro-cladding coatings is investigated. Results exhibit that the surface quality of micro-cladding coatings is seriously influenced by the process parameters, and the optimal laser process parameters: power of 16 W, scanning speed of 20 mm/s, transverse overlap ratio of 0.8 and frequency of 20 kHz (laser energy density of 160 J/mm3) are obtained. Subsequently, the immersion tests are carried out for evaluating the oxidation and corrosion properties of Ni-based coatings, and the coatings with the thickness of 10–15 μm exhibit excellent anti-oxidation and anti-corrosion properties compared to substrate due to the shielding effect of micro-cladding coatings. In oxidation region, Fe3O4 and Fe2O3 oxidation layers are formed on substrate accompanied by large amounts of β-FeOOH, γ-FeOOH and α-FeOOH; however, less oxidation reaction occurs on coating surface. In corrosion region, the substrate is covered by granular structures with more β-FeOOH, γ-FeOOH and a few α-FeOOH, and the coating surface is quite smooth with few defects of exfoliation.

Effect of process parameters and heat treatment on the properties of stainless steel CX fabricated by selective laser melting

The present work envisages the effects of three heat treatment processes, i.e. solution treatment (ST), aging treatment (AT) and solution aging treatment (ST+AT) on the microstructure and mechanical properties of a new type of martensitic stainless steel CX (SS-CX) alloy formed by selective laser melting (SLM) with Cr and Ni as the main components. The results revealed that the densest parts with a few tiny pores were fabricated at optimized laser process parameters (laser power 340 W, scanning speed 850 mm/s, hatch spacing 0.1 mm). The SS-CX that underwent the SLM process was mainly composed of the martensite and retained austenite, and has a tensile strength of 1058 MPa and an impact toughness of 57.7 J. After ST at 900 °C for 1 h, the micro-segregation disappeared, the retained austenite of the as-built transformed into martensite, Ni and Al dissolved in the matrix to form supersaturated solid solution, and a reduction of the mechanical properties of the SS-CX was observed. When the SS-CX was aged at 530 °C for 3 h (AT), part of the martensite in the as-built recovered to austenite, and the precipitated particles with the mechanical properties strengthened. When the SS-CX was solution-aged at 900 °C for 1 h and then 530 °C for 3 h (ST+AT), the retained austenite of the as-built transformed completely into martensite, and the dissolved elements in the solution treatment precipitated again, forming the precipitation particles composed of β-NiAl. The precipitated particles increased rapidly the tensile strength and the surface hardness of the SS-CX with values of 1683 MPa and 50.4 HRC, respectively, thereby indicating that the SS-CX exhibited a good comprehensive property.

Laser Cladding of PAC 718, Tribaloy T-700 and METCO 41 C Hard Facing Powders on AISI SS 304L Substrate

The present investigation aims to deposit the three different hard facing powder (Triboloy T-700 and PAC 718, and TETCO 41 C) on SS 304L using laser cladding technique. The single and overlapped clad track was deposited using 2 kW laser power system. The optimized laser process parameters and 50% overlap clad track was used to deposit a large surface area. The optimum laser process parameters were finalised using single clad structure study. The cross-sections of the clad layers were used to obtain the microstructure and micro-hardness from different regions namely, clad layer, diffusion layer, and substrate. Throughout the study, the laser power was kept constant i.e. 1.2 kW. For single clad deposition, the scanning speed and powder feed rate varied from 0.3 to 0.5 m/min and 4 to 9 g/min, respectively. T-700 and PAC 718 shows uniform developing micro-structure while METCO 41 C shows the development of mixed dendritic and cellular type microstructure. The Triboloy shows the maximum surface hardness of 534 Hv, 321 Hv for PAC 718, and 294 Hv for METCO 41 C.

Formation of bionic surface textures composed by micro-channels using nanosecond laser on Si3N4-based ceramics

Bionic surface textures exhibit excellent properties in improving the friction and wear resistance. To obtain the micro-channel bionic textures with high-quality on Si3N4/TiC ceramic surface, the effect of laser process parameters by using a nanosecond laser with 1064 nm wavelength on micro-channel surface quality and geometry is studied. The surface morphology, depth and width of the micro-channels are examined by scanning electron microscope (SEM) and confocal laser scanning microscope (CLSM). The surface compositions of heat-affected are detected by energy dispersive spectrometer (EDS). Results show that the surface morphology and geometry of the micro-channels are seriously influenced by the laser process parameters. Higher laser power, lower scanning speed, higher frequency and overscan are prone to produce larger channel depth and width due to more accumulated energies. The optimal laser process parameters of the micro-channels are obtained, correspondingly the micro-channel depth and width are about 40–45 μm and 55–60 μm, respectively; meanwhile, it is found that the oxidation occurs in the heat-affected zone. Finally, five kinds of bionic surface textures orderly composed by micro-channels (square, circle, diamond, hexagon and sector) are fabricated on Si3N4/TiC ceramic surface based on the optimal laser process parameters.

Routing a glass substrate via laser induced plasma backward deposition of copper seed layer for electroplating

The pursuit of routing a transparent material has been a compelling challenge for decades. Inspired by the existing fabrication techniques of laser assisted deposition, a novel composite process combining laser induced plasma backward deposition (LIPBD) with succeeding electroplating was proposed for routing a glass substrate in a cost-effective way. With optimized laser processing parameters and electroplating process, a dense copper pattern with mass content of Cu as high as 98.41% was achieved, which also verified superior reliability and stability under the circulation ultrasonic cleaning and strip pulling test. The successfully fabricated micro-circuit on the glass substrate demonstrated that the simple but powerful LIPBD technique possesses the flexibility and feasibility on enormous potential applications in routing micro-circuits on glass substrate.

Effect of pore-forming agent quantity on pore structure, phase composition, micro-hardness of gradient bioceramic coatings under optimal laser process parameters

Titanium-based gradient bioceramic coating fabricated by laser cladding has been studied due to its excellent comprehensive performance and potential value in biomaterials. However, pore sizes of the coating prepared using traditional laser cladding technique are typically too small which can reduce its osteogenesis performance. To address this issue, a porous gradient bioceramic coating is successfully prepared on a titanium alloy surface by adding a pore-forming agent to the coating powder with subsequent laser cladding process. The bioceramic coating prepared with the optimized processing conditions (output power P = 1.8 kW, scanning speed V = 240 mm/min, and spot diameter D = 4 mm) exhibits a flat surface that comprises of a uniform enamel microstructure. The coating is metallurgically bonded to the substrate with a low number of microcracks. When the amount of pore-forming agent A = 2.5 wt%, the distribution of pores in coating becomes more uniform. When A = 2.5 to 10 wt%, the most probable pore size is 2.5 μm. It is shown that pore-forming agent quantity A = 2.5 wt% has a significant advantage in producing more large-sized pores in the coating. The number of pores in coating shows a trend of decreasing first, then increasing, and then decreasing. The coating phase consists of HA, β-TCP, TiO2, CaTiO3, etc., which is consistent with the coating material without pore-forming agent. In general, microhardness gradually decreases with increasing pore-forming agent quantity. The maximum microhardness values of coatings with and without pore-forming agent are 976 HV0.2 and 2086 HV0.2, respectively. Therefore, with the addition of a suitable amount of pore-forming agent, a porous bioceramic coating can be fabricated by an optimized laser cladding technique. This porous morphology will be beneficial for improving the osteogenic properties of the coating.