Product Code: ICA10_1103

Process Parameters Analysis of High Power Direct Diode Laser Cladding
Authors:
Soundarapandian Santhanakrishnan, Research Center for Advanced Manufacturing, Southern Methodist University; Dallas TX USA
Fanrong Kong, Research Center for Advanced Manufacturing, Southern Methodist University; -
Radovan Kovacevic, Research Center for Advanced Manufacturing, Southern Methodist University; -
Presented at ICALEO 2010

Nowadays, high-power direct diode laser (HPDDL) is successfully used in industry as a versatile tool for repairing worn-industrial parts by selective coating. HPPDL based cladding is an economical process to increase the wear and corrosion resistance properties of worn-industrial parts. In this study, a 2-kW HPDDL of 808 nm in wavelength, rectangular-shaped laser spot of (12 mm-1 mm) with uniform distribution of laser power is used to carry out the experiments. A tool steel H13 is cladded on the substrate of AISI 4140 steel. A number of experiments are carried out by changing the laser power level from 1200 W to 1800 W, scanning speeds from 5 mm/s to 10 mm/s and the powder feed rate of 0.7 g/s to produce different clad sizes. An experimentally based finite element (FE) thermal model is developed to predict the cross-sectional as well surface temperature of cladding. The temperature-dependent material properties and phase change kinetics are taken into account in the model. As-used experimental boundary conditions are adopted in this model. The acquired temperature field from FE model is coupled with thermo-kinetic equations to obtain the hardness. The FE thermal model results are verified with the experimental results to optimize the processing parameters. The optimized processing parameters, including laser power, scanning speed, and powder feed rate are used to achieve a uniform cladding and hardness as well.

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