A theoretical processing map for laser cladding: experimental validation with laser cladding of Ti-6Al-4V powder on a Ti-6Al-4V substrate

A theoretical processing map for the laser cladding of Ti-6Al-4V powder on a Ti-6Al-4V substrate was developed. The map was constructed with the aid of a new analytical model for laser cladding, which is detailed in this paper. The map is a series of loci that relate laser traversing speed with laser power for a given melt pool depth and clad height. Several of the developed parameters were experimentally trialled on Ti-6Al-4V clad on Ti-6Al-4V and produced clads of sound metallurgical quality. These maps would be useful for industrial engineers developing new cladding procedures or the research engineer developing understanding of the fundamental aspects of laser cladding. Additive manufacturing or laser engineered net shaping (LENS) could also use this type of map for the development of process parameters.