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A mathematical model of laser cladding repair

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Abstract

To obtain more accurate geometric features of laser cladding layer repair for Invar alloy, an integrated model of the laser cladding repair process is formulated and evaluated. The model evaluates geometric features, namely, the width, contact angle or height of cladding layer, and dilution rate for a given laser power, scanning speed, powder feed rate, and height of the cladding layer or contact angle. First, a model is presented that can ensure the powder from the nozzles melts completely before it hits the base material. Second, a model of the geometric characteristics of cladding layer is developed to determine how the scanning speed and powder feed rate affect the contact angle. Third, a model of the dilution rate is provided to account for the energy absorbed by the base material. The laser power which filters through the powder is absorbed by the base material. Then, the laser power is reflected by the base material, attenuated by the powder, and partly deflected back to the base material. In addition, the powder absorbs part of the attenuated power and surrenders it to the base material. Incidentally, the microstructure of the cladding layer responds to the super-cooling degree of the liquid-solid interface. The results show that the mathematical model is well supported by the experimental results.

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Funding

Financial support of the project was received from the open fund of the State Key Laboratory of Additive Manufacturing, China academy of engineering physics (ZM17002) and the Key Laboratory of High and New Technology Project of Changzhou (CM20183004).

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People’s Republic of China

    Shichao Zhu, Wenliang Chen & Liping Ding

  2. College of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 211106, People’s Republic of China

    Xiaohong Zhan

  3. China Academy of Engineering Physics, Mianyang, 621054, People’s Republic of China

    Qi Chen

Authors
  1. Shichao Zhu
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  2. Wenliang Chen
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  3. Liping Ding
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  4. Xiaohong Zhan
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  5. Qi Chen
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Correspondence to Liping Ding.

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Zhu, S., Chen, W., Ding, L. et al. A mathematical model of laser cladding repair. Int J Adv Manuf Technol 103, 3265–3278 (2019). https://doi.org/10.1007/s00170-019-03588-3

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  • DOI: https://doi.org/10.1007/s00170-019-03588-3

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