A physical modeling and predictive simulation of the laser cladding process

Wirth, Florian; Wegener, Konrad

doi:10.1016/j.addma.2018.05.017

Cited by 73 publications

(36 citation statements)

References 22 publications

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“…Likewise, a smaller outside radius indicated a smaller substrate volume, which caused an accumulation of more condensed laser energy, resulting in a larger substrate melted zone area (A 2 ). Hence, the dilution rate increased according to Equation (1). Under relatively high laser power, the influence of the outside radius on the dilution rate was negligible.…”

Section: Analysis Of Dilution Ratementioning

confidence: 95%

“…In addition, the increased laser power extended the lifetime of the molten pool, which further increased the area of the substrate melted zone (A2) [22][23][24]. Thus, the dilution rate increased according to Equation (1).…”

Section: Analysis Of Dilution Ratementioning

confidence: 99%

“…Laser cladding is an additive manufacturing technology that melts the cladding power by the laser energy and deposits the coating on the substrate. It is a complex process because clad properties are affected by thermodynamics, fluid dynamics, energy absorption, bonding properties, and wettability [1,2]. Because of the high energy density during the process, coatings are deposited with precise dimensions and a high production efficiency with minor heat-affected zones, low dilution rates, and outstanding metallurgical bonding.…”

Section: Introductionmentioning

confidence: 99%

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Investigation of Geometric Characteristics in Curved Surface Laser Cladding with Curve Path

Lian

Zhang

et al. 2019

Metals

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Laser cladding on curved surfaces is essential in industrial applications for restoration and remanufacturing of high-value parts. This study investigated the influence of different factors on clad width, clad height, and dilution rate in curved surface laser cladding with curved path. Mathematical models were developed using central composite designs to predict these geometric characteristics by controlling laser power, scanning speed, gas flow, and altering the outside radius of the cylindrical substrate. Analysis of variance and response surface methodology indicated that clad width increased with increasing laser power and reducing scanning speed. Clad height positively correlated to laser power and negatively correlated to the outside radius of the cylindrical substrate. Increasing the laser power while decreasing the scanning speed led to an increase in dilution rate. Afterwards, the geometric characteristics of the clad were improved by optimizing these factors with the target to maximize clad width and height as well as to minimize dilution rate. The difference between model predictions and experimental validations for clad width, clad height, and dilution rate were 3.485%, 3.863%, and 6.566%, respectively. The predicted accuracy was verified with these models, and they were able to provide theoretical guidance to predict and control the geometric characteristics of curved surface laser cladding with a curved path.

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Section: Analysis Of Dilution Ratementioning

confidence: 95%

Section: Analysis Of Dilution Ratementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Investigation of Geometric Characteristics in Curved Surface Laser Cladding with Curve Path

Lian

Zhang

et al. 2019

Metals

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“…These analytic results have varying levels of sophistication, spanning from overly simple models that lack detail but prove very useful in practical applications, up to complex analytic results that exhibit more accurate predictions, but can be unwieldy to apply [23,24] . Relaxation of assumptions and the introduction of complex phenomena, such as radiation pressure and surface tension effects, take physics-based models from analytically solvable into the numerically solvable regime [25][26][27][28] . Though other discretization techniques have been tried, finite element models furnish the most usable numerical method to solve these complex sets of equations.…”

Section: Planned Submission To a Special Issue Of Materials Internationalmentioning

confidence: 99%

Machine Learning Predictions of Single Clad Geometry in Directed Energy Deposition

Juhasz¹

2020

Preprint

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Within the Additive Manufacturing area of Directed Energy Deposition (DED), single clad geometry prediction has been well covered within the literature. Currently, the two accepted methodologies of geometry prediction are physics numerical simulation, and semi-empirical regression. This work seeks to add a viable alternative through machine learning techniques. Machine learning has enjoyed many successes in the past few years due to the availability of large datasets for which these techniques scale beautifully. However, in small, high variance, tabular datasets, such as most results from physical experimentation, these techniques suffer. Presented here is a selection of machine learning methodologies which are used to extract models that perform and generalize well. Neural Networks (NNs), Gaussian Process (GP) modeling, Support-Vector Machines (SVMs), and Gradient Boosted Decision Trees (GBTs) for regression and classification are explored in this paper. These four methodologies will be applied to a small dataset containing some single clad data available in the literature and previously unpublished experimental results of this author. These techniques produce models not only with good agreement with experimental data, but also non-material specific generalizable results. Lastly, a discussion of data augmentation using Generative Adversarial Networks (GANs) with preliminary results put forth to illustrate unique, exploitable advantages capable within the machine learning paradigm.

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“…The laser cladding is a manufacturing technique, which uses absorbed laser energy to deposit clad layers of improved properties onto a given substrate [1,2]. The clad material can be deposited by several ways, among which powder injection is found most effective in most cases [3].…”

Section: Introductionmentioning

confidence: 99%

Development and characterization of multilayer laser cladded high speed steels

Rahman¹,

Capuano²,

Meer³

et al. 2018

Additive Manufacturing

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Two high speed steel (HSS) alloys were laser cladded on 42CrMo 4 steel cylindrical substrate by using a 4 kW Nd:YAG laser source. After optimization of the laser material processing parameters for single layers, multilayered clads were produced. Microstructural characterization of the laser deposits constitutes studies of the carbides and matrix, which was done by using Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), Electron Backscattered Diffraction (EBSD) and High Resolution Transmission Electron Microscopy (HRTEM). The strengthening mechanism of LC1 (Fe-Cr-MoW -V) was comprised of a martensitic matrix and retained austenite along with networks of VC and Mo 2 C eutectic carbides. Cr enriched fine carbides (Cr 7 C 3 and Cr 23 C 6) were embedded within the matrix. During laser cladding of the multilayer

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A physical modeling and predictive simulation of the laser cladding process

Cited by 73 publications

References 22 publications

Investigation of Geometric Characteristics in Curved Surface Laser Cladding with Curve Path

Investigation of Geometric Characteristics in Curved Surface Laser Cladding with Curve Path

Machine Learning Predictions of Single Clad Geometry in Directed Energy Deposition

Development and characterization of multilayer laser cladded high speed steels

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