Simulation study on laser cladding on preplaced powder layer with a tailored laser heat source

This study proposes a tailored laser heat source model for the finite element analysis of the laser cladding process. The beam characteristics, including wavelength, beam radius, TEM mode and focusing conditions, were comprehensively considered in the heat source model. The model was integrated in a SYSWELD package to predict the temperature distribution and clad bead profile during laser cladding of preplaced cobalt powder layer on a steel substrate. Cladding process parameters were evaluated by varying the TEM mode, focusing conditions, wavelength and scanning speed. Single mode and tailored multi-mode TEMmixed laser beams were established for simulation. The numerical results were verified by performing a laser cladding experiment under the same conditions as the numerical model. The clad bead geometries predicted from the numerical simulation agreed well with those obtained from experiment. Thanks to the comprehensive feature of the proposed tailored laser heat source model, it also could be well applied to the numerical simulation of other laser material processes.

► A tailored laser heat source model for FE-analysis on laser cladding is proposed.
► Laser beam characteristics and laser cladding parameters are considered in the model.
► Clad bead profile and isotherms of laser cladding on preplaced Co-alloy are predicted.
► The numerical result of laser clad bead profile agrees well with an experimental one.