Laser surface cladding: The state of the art and challenges

Abstract

Laser cladding is a process whereby a new layer of material is deposited on a substrate by laser fusion of blown powders or pre-placed powder coatings. Multiple layers can be deposited to form shapes with complex geometry. This manufacturing process has been used for material surface property modification and for the repair and manufacture of three-dimensional components. Laser cladding has attracted extensive research over the past 30 years. Over 2000 research papers have been published in journals and international conferences. Research in laser cladding covers many scientific issues, including processing techniques, physical and chemical properties of deposited materials and clad—substrate interfaces, microstructure and phases, rapid solidification phenomena, modelling and simulation, and systems engineering and applications. This article, focusing on the rapid heating/cooling processes and material response, summarizes the state of the art on two fundamental scientific aspects: rapid solidification and the material characteristics. The article includes a review of the microstructural refinement, extended solid solution, metastable phases, amorphous structure, and directional solidification. In addition, the article discusses the progress and state of the art in laser cladding of commercial alloy powders, carbides and intermetallics, in-situ synthesized particulate reinforced metal matrix composite coatings, compositional gradient materials, and alloy development. Laser cladding is capable of producing materials with designed macro/microstructures and properties.

Laser cladding assisted by induction heating of Ni–WC composite enhanced by nano-WC and La2O3

“…Recently, laser cladding has been an easy and effective approach in fabricating parts with MMC coatings compared with conventional techniques such as thermal spraying, plasma spraying, and arc welding. Laser-cladded ceramic coatings exhibit superior mechanical properties, low dilution, good metallurgical bonding, and lower metallurgical defects [2].…”

Multiphysics simulation of laser–material interaction during laser powder depositon

“…The laser cladding process is defined as the process in which laser beam is used to fuse a material which has different metallurgical properties than the substrate, whereby only a very thin layer of the substrate has to be melted in order to achieve metallurgical bonding with minimal dilution of added material and substrate so that the original properties of the coating material are maintained [2]. In practice, laser cladding makes possible to solve problems such as wear of diesel engine exhaust valves [3], wear of tools made of high speed steel [4], reparation of mold steels [5], corrosion of gas turbine blades [6], and other problems that would be impossible solving using conventional methods, like heat treatment [7].…”

Laser Surface Engineering of Magnesium Alloys: A Review

“…Although the process has been used extensively for repairing of components, the process also presents tremendous potential for producing protective surfaces. 26,51,52 Considering the issues related to wear and corrosion of Mg alloys, LSC is also attractive for improving the surface properties of these alloys.…”