In-Situ Monitoring of Melt Pool Dynamics in Laser Cladding using Numerical Simulation and Spectral Diagnostics

Document Type : Research Article

Authors

1 Iranian National Center for Laser Science and Technology

2 Department of Physics, University of Guilan

Abstract

Online Monitoring and Control of melt pool dynamics play a crucial role in determining the quality of clad layers in laser additive manufacturing processes. This study presents a hybrid approach that combines numerical simulation using the Goldak model with real-time monitoring via Laser-Induced Breakdown Spectroscopy (LIBS) in the laser cladding process of Inconel 718 alloy on 304 stainless steel substrate. The precise modeling of the thermal dynamics of the melt pool was performed on 64 cladding samples, and the cross-sectional dimensions and dilution percentage were validated against experimental measurements. To minimize model error, spectral characterization was employed for real-time monitoring of melt pool variations, providing highly accurate data on local melt pool temperature and elemental composition. The plasma temperature extracted from chromium emission lines in the spectral window of 400 to 500 nm effectively tracked the melt pool temperature variations based on input parameters, while the intensity ratio of nickel (wavelength 361.93 nm) to iron (wavelength 382.94 nm) quantified the dilution of the clad layer. This approach enables dynamic calibration of process input parameters, ensuring uniform clad quality through real-time control of the melt pool.

Keywords

Main Subjects

References

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Amirkabir Journal of Mechanical Engineering
Volume 56, Issue 9
2024
Pages 1275-1302

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