Investigation of meltpool characteristics and correlations during laser cladding using a finite element modelling approach Available to Purchase

An important goal in the optimization of the laser cladding process is reducing the degree of dilution, while maintaining sufficient bounding with the substrate material. The dilution depends on process settings like scanning speed, laser power and powder mass rate. To optimize process settings with respect to the dilution, while maintaining a good adherence between the clad layer and the substrate, usually an expensive series of experiments is performed. Optimal process settings however depend on the material properties and geometry and initial substrate temperature as well. These factors change considerably during the cladding process, and adjusting of the process settings are necessary. To control the dilution real-time, an indirect method has to be used, as the dilution is hard to measure real-time. Therefore, observable characteristics that correlate well with the dilution have been identified. The correlation between observable meltpool characteristics and dilution is investigated using a Finite Element Model of the cladding process. Simulations are performed for different combinations of speed, laser power (distribution) and substrate temperature. A high correlation between meltpool width and dilution was found, being almost independent of the process settings and substrate temperature.