Optimization method for the overlap rate of laser cladding using a variable fitting function

The objective of this study is to enhance the overlap rate in the preparation of a cladding layer to achieve a flat cladding surface. A novel optimization method is proposed that employs variable fitting functions—such as the Lorentz peak function, single-phase exponential decay, and Voigt function—to match the cladding layer height information to the overlap rate with higher precision. Utilizing these specific fitting functions allows for a tailored optimization process based on varying material and process conditions. Experimental results using RCF103 alloy demonstrated that our method could improve the overlap rate optimization by up to 15% compared to the traditional techniques, achieving a flatter and more uniform cladding layer.