Optimization of a Non-Uniform Fe45 Powder Laser Cladding Process Based on Orthogonal Test

Table 1. Orthogonal test scheme
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Table 1. Orthogonal test scheme
No. Laser power /W Scanning speed /(mm·s^-1) Powder feeding rate /(g·min^-1) Defocusing amount /mm
1 1800 5 15 -5
2 1800 10 20 0
3 1800 15 25 +5
4 2100 5 25 0
5 2100 10 15 +5
6 2100 15 20 -5
7 2400 5 20 +5
8 2400 10 25 -5
9 2400 15 15 0

Table 2. Judgment criteria of macro surface quality

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Table 2. Judgment criteria of macro surface quality

Item	Excellent100‒90	Very good<90‒80	Good<80‒70	Accepted<70‒60	Failed<60
Surface topography	The cladding layer is completely combined with the matrix, the surface of the cladding layer is smooth and the slag is very little	The cladding layer is completely combined with the matrix, the surface of cladding layer is smooth, and the slag is little	The cladding layer is completely combined with the substrate,the surface of cladding layer is rough, and the slag is relatively large	There is a small amounts of non-fusion between the cladding layer and the matrix, the surface of cladding layer is rough, and the slag is large	There is a lot of unfused defects between the cladding layer and the matrix, the surface of cladding layer is rough and the slag is very large
Defect	No cracks, no pores	No cracks, few pores	No cracks, few pores	Small cracks, lots of pores	Large cracks, lots of pores
Dilution rate	6%‒13%	14%‒20%	21%‒29%	30%‒37%	38%‒48%

Table 3. Surface morphology and defect scores and dilution rate of the cladding layer
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Table 3. Surface morphology and defect scores and dilution rate of the cladding layer
No. Surface topography score Defect score Dilution rate /%
1 75 70 16.1
2 80 80 0
3 60 65 4.1
4 80 75 0
5 75 70 46.4
6 65 60 18.3
7 80 85 22.8
8 85 70 24.0
9 75 75 21.4

Table 4. Range analysis

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Table 4. Range analysis

Project	Laser power（A）	Scanning speed（B）	Powder feeding rate （C）	Defocusing amount（D）
Macroscopic feature	8.3	13.3	0	6.6
	Order of influence：R_B>R_A>R_D>R_C
	Superior level combination: A₃B₂C D₂
Imperfection	8.3	10	5	10
	Order of influence：R_B=R_D>R_A>R_C
	Superior level combination：A₃B₁C₂D₂
Dilution rate	16	10.5	18.6	17.3
	Order of influence：R_C>R_D>R_A>R_B
	Superior level combination:A₁B₁C₃D₂

Table 5. Fuzzy matrix evaluation results

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Table 5. Fuzzy matrix evaluation results

No.	Matrix
1	B₁=[0.07，0.20，0.50，0.20，0.03]
2	B₂=[0.10，0.20，0.43，0.17，0.10]
3	B₃=[0，0，0.10，0.43，0.47]
4	B₄=[0.10，0.10，0.37，0.27，0.17]
5	B₅=[0，0.07，0.23，0.37，0.33]
6	B₆=[0，0.07，0.13，0.53，0.27]
7	B₇=[0.23，0.33，0.40，0.03，0]
8	B₈=[0.07，0.10，0.27，0.23，0.33]
9	B₉=[0.17，0.23，0.40，0.17，0.03]

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Candong Zhang, Linsen Shu. Optimization of a Non-Uniform Fe45 Powder Laser Cladding Process Based on Orthogonal Test[J]. Laser & Optoelectronics Progress, 2021, 58(5): 0514006

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