Geometric Accuracy and Mechanical Property Enhancement of Fe-Based Alloy Layers in Wide-Beam Laser Direct Energy Deposition

Laser direct energy deposition (LDED) has been widely employed in surface modification and remanufacturing. Achieving high-precision geometries and superior mechanical properties in cladding layers remains a persistent research focus. In this study, an Fe-based alloy was deposited on an AISI 1045 substrate via a wide-beam laser cladding system. Single-track multi-layer samples were prepared with varying z-increment (Zd), interlayer dwell time (TI) and laser scanning speed (V) values. The geometry, microstructure, microhardness and wear resistance of the samples were analyzed. Experimental results showed that an estimated Zd can ensure a constant standoff distance of the laser head and resulting geometric accuracy improvement. Planar grains form at the layer–substrate bonding interface and transition to columnar grains adjacently, while dendrites and equiaxed grains are distributed in the middle and top regions of the layer. The coating layer exhibits much better wear resistance and friction properties than the substrate. The cooling rate can be substantially increased by either raising V or prolonging TI, resulting in refined grain structures and enhanced microhardness. Real-time monitoring and controlling the mean cooling rate have been demonstrated to be effective strategies for enhancing cladding layer performance.