Influence of Process Parameters on Flatness During Single-Track Laser Cladding

During the laser cladding process, poor flatness of the cladding track can cause the surface structure to be uneven or corrugated, affecting the geometrical accuracy of the workpiece. Adjusting process parameters is an effective way to achieve high cladding track flatness. This study established a mesoscale model of the laser cladding process for CoCrMoSi powder to simulate the formation of a single cladding track. Subsequently, the formation mechanism of cladding track flatness was revealed by analyzing the flow within the molten pool and the solidification behavior of the molten pool edge. The influences of laser power, scanning speed, and powder feeding rate on flatness were determined through simulations and physical experiments. Finally, a parameter window of flatness was established using simulation and experimental results. The window indicates that high flatness is achieved with a high scanning speed (<i>v</i> > 260 mm/min), high laser power (<i>P</i> > 2300 W), and low powder feed rate (<i>P_f</i> < 5.5 g/min). The accuracy of the numerical model was verified by comparing the simulated results with the experimental measurements.