Experimental laser cladding of 316L based on thermodynamic coupling and numerical simulation study

Abstract This investigation applies COMSOL Multiphysics to model the laser-driven coating of 316L stainless steel on 45 steel substrates, aiming to evaluate the impact of critical operational parameters—laser power intensity, traverse speed, and material feed rate—on the thermal and mechanical interactions as well as dimensional consistency of the fusion zone. A computational framework integrating thermophysical material data was developed to analyze dynamic thermal profiles and their interdependencies with process variables. Experimental validation revealed that optimized settings (laser power: 1800 W, scanning rate: 5 mm/s, powder supply: 15 g/min) produce a homogeneous molten pool configuration, strong interfacial cohesion, and enhanced surface quality. The close agreement between simulated predictions and empirical data underscores the model’s reliability. These outcomes provide a methodological basis for refining laser cladding protocols to improve coating performance and manufacturing consistency.