Mathematical modeling and experimental validation of diode laser cladding with wire feeding

Laser cladding is an important technique for surface modification and repair of large manufactured components. The objective of this work was to better control and understand the diode laser cladding process and to identify the range of process parameters appropriate for qualification of cladding repair procedures in selected materials combinations. To achieve this, the process was experimentally and mathematically investigated. The laser-material interactions were theoretically reviewed. The absorptivity and spatial diode laser power profile was determined by FEM modeling the laser surface heat treatment process and comparing to the experimentally characterized molten pool formed on a 70--30 cupronickel plate under the laser heating. A 2-D FEM model of the laser cladding with wire feeding process was developed and the temperature field was calculated. The calculated temperature matches the micrography results pretty well. A 3-D FEM model of the process was constructed for implementation in SYSWELD or other commercial FEM program. The temperature histories at the clad and substrate interface were measured experimentally by mounting thermocouples close to the clad surface through holes drilled from the back surface. Digital signal filtering was performed to filter the electrical noise in the acquired data in the cladding process.; The results of this work helps to understand the diode laser cladding process for refurbishing of selected components and to identify the range of process parameters appropriate for qualification of cladding repair procedures in selected materials combinations.