Forming mechanism of single-channel multilayer laser cladding Fe60 process under different laser heat source operating mode

Continuous wave (CW) and pulsed wave are the two principal modes of operation used to control the laser heat source. Different laser heat source operating modes have an essential impact on the rapid cooling and heating temperature change rate during the cladding process, which directly determines the cladding layer quality. The laser cladding process is meaningful to quantitatively reveal the mechanism of single-channel multilayer cladding and forming under different laser heat source operating modes. In this article, a multi-field coupled 3D numerical model of the single-channel multilayer cladding process under different laser operating modes was proposed, and the thermal physical parameters of the cladding material were computed on the basis of Calculation of Phase Diagrams method. The mechanism of the impact of distinct operating modes on the multi-field coupled ephemeral evolution process of laser cladding was investigated by using the solid/liquid interface tracking technique, which comprehensively considers the light powder interaction between the powder waist beam and the laser beam under different operating modes. The temperature, flow, and stress fields were computationally solved for a single-channel multilayer cladding process. On the foundation of this study, the impact mechanism of pulse duty cycle and pulse frequency on the cladding behavior of single-channel and multilayers during pulsed laser cladding were dissected. The macroscopic morphology and microstructure of the cladding layer were observed by KEYENCE VH-Z100R ultra-deep field electron microscope, and the feasibility of the model was confirmed. This study provides a significant theoretical rationale for enhancing the cladding quality under different laser operating modes.