Study on the Optimization of Laser Cladding Process Parameters and Overlap Strategies for CuCrZr Copper Alloy Powders

The quality of laser cladding is influenced by a combination of various process parameters, including laser power, powder feed rate, scanning speed, defocus amount, overlap ratio, and the flow rates of the powder feed gas and shielding gas. Taking into account the adjustment characteristics of laser cladding equipment, this paper selects laser power, powder feed rate, and scanning speed as the primary factors of study and systematically analyzes the patterns of their effects on the quality of the cladding layer. Based on the results of preliminary experiments, a single-factor experimental design was formulated, and the experimental results were analyzed according to the established cladding quality evaluation system. By developing an orthogonal experimental design and employing a combination of range analysis and analysis of variance, the optimal combination of process parameters was determined. Subsequently, the overlap ratio and Z-axis lift were derived and calculated using the equal-area method, providing a reference for the rapid estimation of multi-pass and multi-layer cladding coating process Windows.