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Optimization of laser-cladded SS316L/IN625 functionally graded material deposited on a copper substrate for boiler pipe heat exchanger applications

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Abstract

Laser cladding is a surface modification method that can be employed in components under severe operating conditions, such as boiler heat exchangers, to mitigate degradation. However, poor clad quality hinders performance during service. This study employed the hybrid Taguchi-grey relational analysis and artificial neural network (ANN) method to optimize the clad qualities while varying the laser cladding process parameters including laser power, scanning speed, and powder flow rate. Laser cladding process parameters were used in the backpropagation NN model as input, and the grey relational grade was employed as the output of the model to improve the clad properties. The values of performance attributes for microhardness and aspect ratio were increased, whereas surface roughness and porosity were reduced in the fabricated functionally graded stainless steel 316L/Inconel 625 coating. When the ANN model was used to optimize the experimental grey relational analysis conditions, it was found that the 600 W laser power, 700 mm/min scanning speed, and 1.5 g/min powder flow rate enhanced the experimental output. The generated model significantly improved the quality of the laser cladding process. A confirmatory experiment was carried out using ANN optimal parameters, and the fabricated samples were subjected to microscopic analysis to ascertain the influence of process parameters on clad characteristics. Heat treatment was also used to alleviate the tensile residual stresses of the fabricated functionally graded material. Thus, the ANN model and fabricated coating can be utilized effectively to modify the boiler pipe surface.

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Data availability

All the data used is available within the manuscript. Any additional simulation information can be obtained from the first author upon request.

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Acknowledgements

The authors would like to express their sincere gratitude to Mr Samuel Skhosane for assistance in operating the laser cladding machine at Council for Scientific and Industrial Research (CSIR), Pretoria.

Funding

This work was supported by the European Union, Fund No. 2019–1972/5, Project No. 61455. The African Laser Center also funded this work, Fund No. HLHA24X task ALC-R020. Mr Joseph Morake, who is the first author, is the first author to receive the funding.

European Commission,2019-1973/5,Joseph Bophelo Morake,614655,Joseph Bophelo Morake

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Authors and Affiliations

  1. School of Mechanical Manufacturing and Materials Engineering, Jomo Kenyatta University of Agriculture and Technology (JKUAT), Nairobi, Kenya

    Joseph B. Morake, Martin R. Maina & James M. Mutua

  2. Department of Mechanical, Energy & Industrial Engineering, Botswana International University of Science & Technology, Palapye, Botswana

    Eyitayo O. Olakanmi

  3. UNESCO Chair On Sustainable Manufacturing & Innovation Technologies (UCoSMIT), Botswana International University of Science & Technology, Palapye, Botswana

    Eyitayo O. Olakanmi

  4. Advanced Manufacturing & Engineering Education (AMEE) Research Group, Botswana International University of Science & Technology, Palapye, Botswana

    Eyitayo O. Olakanmi

  5. Laser Enabled Manufacturing Research Group, Council for Scientific & Industrial Research, Pretoria, South Africa

    Sisa L. Pityana

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  1. Joseph B. Morake
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Contributions

Conceptualization: JBM. Investigation: JBM, MRM, JMM, EOO, SLP. Methodology: JBM, MRM, JMM, EOO, SLP. Funding acquisition: JBM, EOO, SLP. Writing of the original draft: JBM. Writing of review and editing: JBM, MRM, JMM, EOO, SLP. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Joseph B. Morake.

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Morake, J.B., Maina, M.R., Mutua, J.M. et al. Optimization of laser-cladded SS316L/IN625 functionally graded material deposited on a copper substrate for boiler pipe heat exchanger applications. Int J Adv Manuf Technol 130, 2343–2368 (2024). https://doi.org/10.1007/s00170-023-12764-5

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