Progress in numerical simulation of the laser cladding process

Laser Cladding is one of the developing manufacturing techniques used for diverse applications such as coating, repairing and prototyping. Complex processing phenomena and the formation and growth of thin clad of few micrometres to millimetres range in most cases are yet to be fully understood. However, in recent past, several numerical models have been reported to get some understanding of physical, dynamic and metallurgical phenomena of this process. This article reviews the progress of numerical simulations spanning over three distinct stages of the process to model powder flow dynamics, melt pool and clad properties. For each stage, the governing equations, the effect of process variables and experimental validation techniques have been discussed. Specifically, we have outlined some of the underlying assumptions in the current numerical models which can act as pointers for further improvement of the existing numerical models. Authors recommend that numerical simulation results have to be complemented with experimental results to achieve better clad properties.