Optimization of Process Parameters for Laser-Directed Energy Deposition Coatings of FeCoNi + 1%Y2O3 High-Entropy Alloy Based on Response Surface Methodology

In order to achieve precise shaping control of FeCoNi + 1%Y₂O₃ laser-directed energy deposition (LDED) coatings and to reveal the influence of LDED process parameters on coating morphology, the response surface methodology (RSM) is employed in this study. The process parameters, including laser power, scanning speed, and powder feeding rate, are comprehensively considered, with the dilution rate, width-to-height ratio, and cladding area as evaluation criteria. A regression model is established to analyze both the individual and interactive effects of process parameters on forming quality. The findings indicate that the ideal process parameters are a laser power of 706.8 W, scanning speed of 646.2 mm/min, and powder feeding rate of 12 g/min. Experimental validation shows that the mean actual errors compared to the predicted values for dilution rate, width-to-height ratio, and cladding area are 7.36%, 10.03%, and 3.50%, respectively, proving the reliability of the model. The findings provide a theoretical basis for the prediction and control of the morphology of high-entropy alloy deposited layers with the addition of Y₂O₃.