From statistical analysis to process optimization during cladding using a Nd:YAG laser

Application of statistical methods to optimize the process parameters was achieved by employing full factorial design of experiments, which was accomplished by cladding using stepwise ramped laser power. The correlations between clad geometry and dilution (clad characteristics) and the main process parameters laser power (P_l), cladding speed (v_c), the powder feed rate (m) were obtained through application of variance analysis technique (ANOVA). The obtained correlations between the main processing parameters and the clad characteristics are discussed and a statistical model was developed. The desirability investigations using the developed statistical model were performed by considering the clad geometry, aspect ratio, dilution and hardness. Optimal parameters for cladding Stellite 6 on AISI 420 steel substrate and for cladding Nucalloy 488V on S355 J2 steel substrate were obtained. The optimal processing parameters can be applied to clad other materials with similar chemical compositions.