Product Code: ICAL07_1304

Investigation of Meltpool Characteristics and Correlations during Laser Cladding using a Finite Element Modeling Approach
Authors:
Johannes Hofman, Netherlands Institute for Metals Research; Enschede Netherlands
D.F. De Lange, University of Twente; Enschede Netherlands
J. Meijer, University of Twente; Enschede Netherlands
Presented at ICALEO 2007

An important goal in the optimization of the laser cladding process is to reduce the degree of dilution. This dilution depends on process settings like scanning speed, laser power and powder mass rate. To optimize process settings width respect to the dilution, usually an expensive series of experiments is performed. Optimal process settings however depend on the material properties and substrate temperature as well. These properties change considerable during the cladding process, and adjusting of the process settings are necessary. To control the dilution real-time, an indirect method has been used, as the dilution is hard to measure real-time. Therefore, one or more observable characteristics that correlate well with the dilution have been identified. The correlation between observable meltpool characteristics and dilution is investigated using a Finite Element Model of the cladding process. Simulations are performed for different combinations of speed, powder mass rate, laser power and initial substrate temperature. A high correlation between meltpool width and dilution was found, being almost independent of the process settings and substrate temperature.