Optimization of processing parameters in fiber laser cladding
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ORIGINAL ARTICLE
Optimization of processing parameters in fiber laser cladding Sayeed Mohammed 1 & Zhe Zhang 1 & Radovan Kovacevic 1 Received: 12 June 2020 / Accepted: 2 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Laser cladding of steel is a promising solution to wear and corrosion resistance, and to the improvement of the mechanical properties of the cladded surface. The properties of cladded components depended on the clad geometry. The clad geometry was governed by the processing parameters. In this study, a cored wire with a sheath made of 95 wt% Co and 5 wt% Fe, with an outer diameter of 1.2 mm and an inner diameter of 0.8 mm, was used. A full factorial design was used to optimize the processing parameters in cored wire laser cladding. The design consisted of three main factors: laser power, scanning speed, and cored wire feed rate, each at three levels in addition to the current, laser spot diameter, and stand-off distance. The response functions were clad width, height, aspect ratio (width/height), dilution ratio (penetration area/total fusion area), and the hardness. The mathematical relationships were established by statistical analysis. The optimal values of the parameters were determined from these relationships. The overlay plots were made from graphical optimization to serve as a technical reference for operators in the workshop for laser cladding with a specific material of cored wire. It was found that a laser power of 3.7 to 3.9 kW, a cored wire feed rate of 75 mm/s, and a scanning speed close to 6 mm/s were the optimal values. Keywords Processing parameters . Cored wire . Cladding . Steel
1 Introduction The erosion, wear, and corrosion resistance of steel limited its applications in the extreme conditions. The improvement of these attributes depended on economics, environments, and technical limitations. The cladding was the deposition of protective coating and the more attractive approach in this regard [1]. With an emphasis on cost-efficiency, the laser was at the forefront due to the advent in cutting-edge technology [2]. The oil and gas industry uses deep-hole drilling tools which are constantly subjected to hostile conditions; thus, there is a permanent quest to extend the tool life. In 1960, Maiman discovered the first functional laser [3], but Gnanamuthu at Rockwell International Corporation, CA, used laser for cladding in the1980s [4]. The laser cladding offered a solution by boosting hardness and wear resistance with significant enhancements in service lifetime. The evolution of laser unfolded new frontiers for metal cutting, heat treatment, welding,
* Radovan Kovacevic [email protected] 1
Research Center for Advanced Manufacturing (RCM), Department of Mechanical Engineering, Southern Methodist University, Dallas, TX 75205, USA
glass scribing and engraving, and cladding. The popular lasers were fiber, CO2, Nd:YAG, and high-power direct diode laser. The laser cladding was key to the substrates of complex geometry where the clad can be designe
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