Analysis and prediction on geometric characteristics of multi-track overlapping laser cladding

Building the analytical model between process parameter and results is the prerequisite for explaining the complex process of laser cladding “laser-powder” interaction, as well as the critical guidance for processing conduction, prediction, and control of geometrical characteristics. This paper utilized response surface methodology (RSM) to study the effect on multi-track cladding width, flatness ratio, and dilution among the following major process parameters: laser power (LP), scanning speed (SS), gas flow (GF), and overlapping rate (OR). The experiment was based on four factors and five levels designed to build the model between processing parameters as input and processing results as output by RSM multiple regression analysis. Variance analysis and significant test was utilized to validate the model. By predicting the geometrical characteristics to optimize processing parameters, get the multi-track cladding layer with the maximum width, the minimum flatness ratio, and dilution. The predictive value and experiment results had a difference of 4.17, 3.68, and 3.56%, for width, flatness ratio, and dilution respectively, which provided another validation for this model. The model could be used on controlling of multi-tracking cladding geometrical characteristics, prediction of performance, and optimization of process parameters.