Numerical simulation of temperature profile during laser cladding of nickel powder for in situ repairing

A 3-D Finite Element (FE) model was established to simulate the laser cladding of nickel powder for in situ repairing AISI 410 stainless steel. The temperature distribution field was estimated at six different points using low laser power of 450 W and a scanning speed of 2 mm/s. This study used a moving laser heat source in COMSOL to simulate the laser cladding process. The proposed FE model investigated the temperature field in two cases: (1) in situ repairing the defect by laser cladding without preheating and (2) in situ repairing the defect by laser cladding technique after preheating the cavity made on the substrate. A time-temperature profile was obtained after the simulation in both cases. The results of both cases were compared and analyzed. When the cladding material is poured into the preheated cavity, its temperature rises due to the heating effect obtained from the cavity, resulting in a higher maximum temperature after the cladding process. It was observed that after the cladding process, the maximum temperature was higher in the case of laser cladding after preheating the substrate (2400.49 K) compared to the maximum temperature in cladding without preheating the substrate (1770 K). Therefore, a molten pool is formed, solidifying rapidly to form a clad coating with better metallurgical bonding and enhanced surface properties.