Analysis and prediction of geometrical shapes and dilution rate in laser cladding repair of Ti-6Al-4V alloy.

To accurately characterize the geometric features in the repair of Ti-6Al-4 V alloy, a laser cladding mathematical model was developed and experimentally validated. The model employed a quartic polynomial function to analyze the geometric features of the clad layer, investigating correlations among deposition angle, clad layer width, melt pool depth, and clad layer area. Additionally, it utilized a quadratic polynomial function to characterize the geometric profile of the melt pool, establishing relationships involving clad layer width, melt pool depth, and melt pool area simultaneously. By means of the areas of the cladding layer and the melt pool, the value of the dilution rate can be obtained. Subsequently, the measured and predicted values of the clad layer, melt pool, and dilution rate were compared. The results demonstrated the mathematical model's capability to accurately forecast geometric features in laser cladding. Furthermore, an orthogonal experiment was conducted to investigate how process parameters—laser power, scanning speed, and powder feeding rate—affect the geometric dimensions (height, width, and melt pool depth) of single-pass, single-layer cladding, and to elucidate the underlying reasons. These investigations offered theoretical insights and practical guidelines for controlling the clad layer, melt pool, and dilution rate. [ABSTRACT FROM AUTHOR]