FEM modeling and experimental verification for dilution control in laser cladding

A model for the determination of the clad geometry and dilution in laser cladding is presented. The model uses a novel approach to determine the clad geometry. This involves a mathematical transformation of the balance equations describing the physical effects. The correlation between observable melt pool characteristics and dilution is investigated using this model. Simulations were performed for different combinations of cladding speed, laser power (distribution) and substrate temperature. Simulation results are compared to experimental results, showing a high degree of agreement. A high correlation between melt pool width and dilution was found, which was almost independent of the process settings and substrate temperature. This makes the width an excellent sensor for online dilution control.