Impact of localized surface preheating on the microstructure and crack formation in laser direct deposition of Stellite 1 on AISI 4340 steel

Crack formation in laser cladding of the hardfacing alloy Stellite 1 on AISI-SAE 4340 steel was prevented through locally preheating the substrate prior to the deposition process. Numerical analysis showed that the preheating process helps developing a relatively steadier melt temperature as well as decreasing the cooling rates and consequently the thermal stresses during the subsequent deposition process. Microstructural analysis revealed a thicker cross-section with smoother surface profile, more uniform surface hardness and even distribution of a dendritic morphology in the preheated sample. This confirmed the presence of a well-developed melt pool with a homogeneous composition at solidification. The microstructure of non-preheated sample was, however, considerably non-uniform consisting of macro-scale colonies of dendritic and lamellar (eutectic) structures. The experimental observations, as implied through the numerical results, showed that the preheated sample, in general, reveals more uniform structure and properties making it less prone to cracking during the deposition process.