Stellite Cladding Example

The goal of this project area is to provide a complete physical understanding of the laser cladding process (applied to various materials) and the development of a complete predictive model that will enable optimization of the process and its commercial application to cladding of various engineering surfaces to meet precise specifications. Specific objectives of the research include:

• Find operating conditions that globally optimize the process in order to:
  • maximize laser cladding rate
  • minimize sub-surface flaws
  • maximize clad zone quality
• Investigate the laser cladding mechanism for various materials.
• Develop a predictive transient, three-dimensional thermo-diffusion model for laser cladding.
• Understand the underlying physics of laser cladding.
• Develop guidelines to determine materials for which laser cladding is best suited.
• Develop an economic analysis of laser cladding against current practice

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The study of laser-cladding at Purdue is based on the simultaneous experimental and numerical investigation of the process. The experiments are conducted using three different state-of-the-art set-ups, providing an array of different capabilities.   The existing set-ups provide the capabilities of cladding a surface with a complex contour using a high power direct diode laser (HPDL) due to the seven d.o.f. positioning ability and harmonizing software.  Modeling efforts include prediction of powder flow, melting and solidification, resultant microstructure, deposited layer dimension and resultant residual stresses.   Several models are integrated to provide the comprehensive predictive capabilities. 

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Research Progress:

• Successful laser cladding of various materials has been achieved by preplaced cladding and blown power cladding (see the figures above for Stellite 6 on 1018 steel alloy ).   Deposited tracks no porosity, no cracks and minimal dilution (2-3%).
• A flexible cladding set-up (seven d.o.f.) has been established (see the right figure below).
• Current work includes blown powder cladding, and preplaced cladding of different materials. 
• A predictive numerical model has been developed to predict and optimize operating conditions during the cladding (see figures blow)
• Experimental measurements of powder velocities and temperature during blown powder cladding have been performed to verify the predictive model.

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Cladding Experimental Set-up

Predicted molten pool

Predicted clad geometry

National Science Foundation
Purdue Research Foundation
Indiana 21st Century Research and Technology
Caterpillar
Adiabatics