Numerical simulation and experimental investigation on three-dimensional modelling of single-track geometry and temperature evolution by laser cladding

Investigation of the temperature distribution law in molten pool during the laser cladding process and the varying principle of the forming parts’ cross section sizes to obtain optimum process parameters is essential to improve the precision of deposited parts. In this paper, a three-dimensional numerical single-track processing prediction model (STPPM) in laser cladding was established. The Gaussian distribution heat source was applied. Based on the element birth and death method, the transient temperature field and the geometry of the cladding could be calculated simultaneously by considering the temperature rise of the powder particles, laser energy attenuation and the material phase transition. With the prediction error less than 6.6% for track width and track height, approximately 3.1% for the maximum temperature, numerical simulation results of the track profile agreed well with the experiment results for 316 stainless steel material, indicating the validity of the STPPM. The effects of laser power and scanning speed on the geometry and temperature distribution of cladding were analyzed on the basis of the STPPM and experimentally proved. The results show that track height, width and the temperature in molten pool decreased accordingly with the increase of scanning speed. In addition, track width and the temperature in molten pool increased with the laser power while the track height stabilized. Research in this paper would contribute to minimizing the number of tentative experiments in laser cladding process and the experimental costs, meanwhile improving deposition efficiency during the processing.