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<p>Laser cladding is widely employed to enhance surface properties of engineering components, yet residual stresses generated during the process can compromise structural integrity. This study develops and experimentally validates a thermo-mechanical coupled finite element model to investigate the influence of key process parameters—laser power, scanning speed, and powder feed rate—on residual stress distribution and microstructural evolution during single-track laser cladding. Numerical predictions show close agreement with experimental results, confirming the reliability of the proposed model. Simulation analyses reveal that moderate laser power (1700 W), scanning speed (10&#xa0;mm/s), and powder feed rate (13.5&#xa0;g/min) yield minimal residual stresses, optimal deformation characteristics, and desirable microstructures composed primarily of columnar and equiaxed dendritic grains. Grain coarsening occurs at increased thermal inputs (high laser power or low scanning speeds), whereas faster scanning speeds promote grain refinement through enhanced cooling rates. These findings provide crucial insights for optimizing laser cladding parameters to achieve improved mechanical performance and structural stability.</p>

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Numerical and Experimental Study on the Effects of Process Parameters on Residual Stress in Laser Cladding

  • 期刊论文

  • 发表日期：

    2026年2月21日

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  • Yu-sheng Zhang,
  • Tao Lan,
  • Yang Guo,
  • Gui-jun Mao,
  • Chong Xiang,
  • Hai-tao Wang,
  • Guo-zheng Quan,
  • Jian-sheng Zhang,
  • Jie Zhou

摘要

Laser cladding is widely employed to enhance surface properties of engineering components, yet residual stresses generated during the process can compromise structural integrity. This study develops and experimentally validates a thermo-mechanical coupled finite element model to investigate the influence of key process parameters—laser power, scanning speed, and powder feed rate—on residual stress distribution and microstructural evolution during single-track laser cladding. Numerical predictions show close agreement with experimental results, confirming the reliability of the proposed model. Simulation analyses reveal that moderate laser power (1700 W), scanning speed (10 mm/s), and powder feed rate (13.5 g/min) yield minimal residual stresses, optimal deformation characteristics, and desirable microstructures composed primarily of columnar and equiaxed dendritic grains. Grain coarsening occurs at increased thermal inputs (high laser power or low scanning speeds), whereas faster scanning speeds promote grain refinement through enhanced cooling rates. These findings provide crucial insights for optimizing laser cladding parameters to achieve improved mechanical performance and structural stability.