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<p>Laser cladding, a cutting-edge additive manufacturing and surface treatment technique, involves numerous interactive process parameters and is efficient for constructing intricate structures. In this study, a thermal model utilizing the finite element method (FEM) is formulated to examine the thermal aspects encompassing heat transfer and fluid flow in laser cladding. The COMSOL Multiphysics software is employed, and the melt pool’s free surface is modeled using arbitrary Lagrangian and Eulerian (ALE) methods. Impacts of crucial process parameters such as laser power, scanning speed, and powder feed rate on cladding track geometry, temperature distribution, and velocity are also investigated. Experimental tests using Inconel 625 as the deposition substrate and powder are conducted to validate the simulation model. The average relative error for track width and height are calculated 5.27% and 13%, respectively. Moreover, the validity of the molten pool’s temperature field results is confirmed through temperature measurements and the features of the cladding. The average error in the maximum temperature is found to be 8.9%. The findings indicate a strong concurrence between the proposed Multiphysics simulation outcomes and the experimental results, illustrating the simulation’s capability to elucidate the qualitative connection between process parameters and the geometry and temperature distribution of the cladding track.</p>

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Investigation of cladding track geometry using thermal finite element method in laser cladding additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年5月30日

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  • Milad Ala,
  • Weiwei Liu,
  • Huangqiang Liu,
  • Fengtao Wang

摘要

Laser cladding, a cutting-edge additive manufacturing and surface treatment technique, involves numerous interactive process parameters and is efficient for constructing intricate structures. In this study, a thermal model utilizing the finite element method (FEM) is formulated to examine the thermal aspects encompassing heat transfer and fluid flow in laser cladding. The COMSOL Multiphysics software is employed, and the melt pool’s free surface is modeled using arbitrary Lagrangian and Eulerian (ALE) methods. Impacts of crucial process parameters such as laser power, scanning speed, and powder feed rate on cladding track geometry, temperature distribution, and velocity are also investigated. Experimental tests using Inconel 625 as the deposition substrate and powder are conducted to validate the simulation model. The average relative error for track width and height are calculated 5.27% and 13%, respectively. Moreover, the validity of the molten pool’s temperature field results is confirmed through temperature measurements and the features of the cladding. The average error in the maximum temperature is found to be 8.9%. The findings indicate a strong concurrence between the proposed Multiphysics simulation outcomes and the experimental results, illustrating the simulation’s capability to elucidate the qualitative connection between process parameters and the geometry and temperature distribution of the cladding track.