Numerical analysis to determine critical height for multi layered laser cladding for die repair applications

The residual stress in the components repaired using laser cladding (LC) is of immense importance. A tensile residual stresses in the clad layer or clad-substrate interface region can lead to accelerated fatigue failure. To determine the optimal cladding conditions, it is imperative to identify a critical height of clad layer such that the entire layer is under compressive residual stress. A methodology to determine the critical clad height in a single layer deposition has been developed. However, the deposition of an additional layer can alter the residual stresses in the preceding layer. Consequently, the determination of sub-surface residual stress profile in multi-layered LC is of immense importance for successful restoration of critical components. The current work focuses on the development of a coupled metallo-thermomechanical finite element model in ABAQUS^® for multi-layered laser cladding of CPM9V powder on H13 tool steel. The residual stress evolution along the cross-section has been characterized at different process conditions and the optimal conditions corresponding to the critical height has been identified wherein the deposited layers are under compressive residual stresses.