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A thermo-mechanical model for simulating the temperature and stress distribution during laser cladding process

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Abstract

During the laser cladding process, thermal stresses are induced because of the high-energy input, high temperature gradient, fast cooling rate, and inconsistency of the clad-substrate material. The induced thermal stresses not only increase the crack tendency, but also influence the mechanical performance of the deposited layer. In this study, a three dimensional (3D) uncoupled thermo-mechanical finite element (FE) model was established to simulate the stress evolution of laser cladding of cobalt-based coatings on mild steel A36. The temperature field was simulated first and then used as transient thermal loading to simulate the stress evolution. Stress distributions for three cases: single track on a flat substrate, double-track on a flat substrate, and double-track on a cylindrical substrate, were investigated in detail. To check the accuracy of the simulation results, validation experiments were carried out using an 8-kW high-power direct diode laser. The thermocouples were used to monitor the temperature cycles at several marked points. The cross-sections of single and double tracks on a flat substrate obtained experimentally were compared with the simulation results. The residual stress on the clad was experimentally determined by an X-ray diffraction machine. The experimentally obtained data showed a significant consistency with the prediction results.

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Acknowledgements

The authors would like to thank Andrew Socha, a research engineer at the Research Center for Advanced Manufacturing, for his help in the execution of experiments. The first author, Zhe Zhang, would like to thank Dr. Lin Zhu, a former Ph.D. candidate at the Department of Mechanical Engineering, Southern Methodist University, for his support and encouragement during the preparation of this work.

Funding

This work was financially supported by the NSF’s Grant No. IIP-1539853.

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Authors and Affiliations

  1. Center for laser-aided Manufacturing, Lyle School of Engineering, Southern Methodist University, 3101 Dyer street, Dallas, TX, 75206, USA

    Zhe Zhang & Radovan Kovacevic

Authors
  1. Zhe Zhang
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  2. Radovan Kovacevic
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Correspondence to Radovan Kovacevic.

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Zhang, Z., Kovacevic, R. A thermo-mechanical model for simulating the temperature and stress distribution during laser cladding process. Int J Adv Manuf Technol 102, 457–472 (2019). https://doi.org/10.1007/s00170-018-3127-y

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  • DOI: https://doi.org/10.1007/s00170-018-3127-y

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