Numerical Simulation of Thermal Evolution and Solidification Behavior of Laser Cladding AlSiTiNi Composite Coatings

In order to better understand how a high energy input and a fast cooling rate affect the geometric morphology and microstructure of laser cladding aluminum composite coatings, a three-dimensional (3D) transient finite element model (FEM) has been established to study the temperature field evolution during laser cladding of AlSiTiNi coatings on a 304 stainless steel substrate. In this model, a planar Gauss heat source and a temperature selection judgment mechanism are used to simulate the melting and solidification process as well as the geometric morphology of the laser cladding coatings. The differences in physical characteristics of the cladding materials before and after melting are considered. The results of thermal simulations, including temperature history, temperature gradient, and solidification rate, of the laser cladding coatings are investigated. Corresponding experiments, conducted using an IPG-YLS-5000 fiber laser, are used to verify the simulation results. The experimental observations agree well with the theoretical predictions, which indicates that the established model is valid.