Laser cladding of Ni based powder on a Cu-Ni-Al glassmold: Influence of the process parameters on bonding quality and coating geometry

Laser cladding of a Ni based powder on cupro-nickel-aluminum (Cu-Ni-Al) substrate was performed with a 4 kW continuous laser. The Cu-Ni-Al alloy is used for its thermal properties in glass mold industry. The role of the Ni based alloy clad is to protect the mold without affecting its thermal properties by limiting the heat-affected zone. The objective of this research is to produce a well bonded Ni based melted powder without pores or cracks and with a very small dilution zone on a non-planar surface (curved section). The impact of the process parameters such as laser power, scanning speed and powder feeding rate on the coating geometry was investigated with an experimental design technique analysis using the ANOVA (Analysis of variance) method. It was used to determine and represent the influence of each process parameter on the coating geometry (width, height) and the bonding quality. This ANOVA analysis led to a parameter combination to optimize the bonding quality between the Ni coating and the Cu-Ni-Al substrate taking into account the industrial geometrical constraints. More, an analytical calculation allowed to estimate the power necessary for bonding as a function of laser scanning speed and powder feeding rate.