Parametric investigation and optimization for CO₂ laser cladding of AlFeCoCrNiCu powder on AISI 316

Abstract

The purpose of the current investigation is to analyze the effect of the operating parameters of laser-assisted cladding process on clad height, clad depth, clad width and the percentage dilution in a cladding of AlFeCuCrCoNi high-entropy powder on SS-316 through CO2 laser and to optimize the cladding process parameters for optimum dilution. The experiments were designed by the full factorial method and analyzed by ANOVA. The analysis results indicate that dilution is most influenced by scanning speed followed by the powder feed rate. The outcomes of the single clad profile in terms of dilution, microhardness, composition and the microstructures produced in various cladding conditions are investigated briefly, and through which the optimum set of laser cladding operating parameters for maximum hardness of the clad material is determined. The optimum cladding conditions in the experimental range were obtained at 4 g/min powder feeding rate, 500 mm/min laser scanning speed and 1.1 kW laser beam power through multi-response optimization. Furthermore, the multi-track coating with 60% overlapping ratio was deposited using optimized parameters. The wear behavior of multi-track coating was determined using pin on disk wear apparatus with applied load of 20 N, sliding speed of 300 RPM and test duration of 15 min. The pin on disk wear test results indicates that the friction coefficient of SS-316 is larger than that of high-entropy alloy cladded SS-316. The wear resistivity of SS-316 improved by 40.35% after laser-assisted high-entropy alloy coating, which confirms that the laser cladding layer plays an essential role in enhancing the wear resistance capability of austenite steel.

An Overview of Technological Parameter Optimization in the Case of Laser Cladding

“…The experimental results show that the laser power and powder feeding rate greatly influence the deposition efficiency and dilution, and the porosity is mainly related to the raw material. Meng [104], Menghani [105], Mohammed [106], and Liu et al [107] used the desirability function approach to identify the optimum magnitude of the process parameters in the laser cladding process to obtain better cladding quality and geometry. Rasheedat [108] and Moradi et al [109] designed a complete factorial experiment, ran many experiments with different process parameters, and obtained the best process parameters through the Design Expert statistical software.…”

Prediction Method for High-Speed Laser Cladding Coating Quality Based on Random Forest and AdaBoost Regression Analysis

“…It is mainly designed and developed by factor design, Taguchi design, central composite design (CCD), and response surface method (RSM) [ 19 ]. Menghani [ 20 ] employed a full factorial design approach to briefly explore the overlap rate, microhardness and microstructure of individual coatings while determining optimal cladding conditions through multi-response optimization. Khorram [ 21 , 22 ], respectively, utilizing response surface methodology and central composite design for cladding 75Cr 3 C 2 + 25(80Ni20Cr) coating, investigated its influence on geometric parameters (width, height, and cladding angle), dilution rate, and hardness.…”

Engineering Process Optimization and Quality Stability Control of High-Speed Laser Cladding Coatings Based on AHP-FCE

“…In order to investigate the effects of laser power, scanning speed, and powder feeding speed on the track geometry of YCF104 clad tracks, Zhao [11] designed 125 sets of single-factor experiments to examine their impact on the cross-sectional area, width, and depth of the track as well as the width and depth of the heat-affected zone. Menghani [12] employed a full factorial design approach to briefly explore the overlap rate, microhardness, and microstructure of individual coatings while determining optimal cladding conditions through multi-response optimization. Khorram [13,14], respectively utilizing response surface methodology and central composite design for cladding 718 CrC + 75 (25Ni80) coating, investigated its influence on geometric parameters (width, height, and cladding angle), dilution rate, and hardness.…”