Simplification and experimental investigation of geometrical surface smoothness model for multi-track laser cladding processes

摘要： The formation of large area parts requires construction of multi-track laser cladding layers which are significantly influenced by the overlapping coefficient. The geometrical model of optimal overlap ratio to obtain least surface fluctuation of multi-track claddings is derived into a simpler form in terms of the aspect ratio of single-track clads. The error analysis further demonstrates the effectiveness of these models. Multi-track single layer claddings are fabricated at a series of overlap ratios under two process conditions. The surface states of cladding layers are then evaluated by two types of smoothness definitions with two fitting methods to study the optimal overlap ratios. The results show that the experimental optimum conditions identified by two methods are slightly different from each other. The theoretical prediction is in good agreement with the experimental one when the aspect ratio is great enough to support the model assumptions.