Statistical modeling and optimization of clad geometry in laser cladding of Amdry 365 on Hastelloy X superalloy with response surface methodology

The aim of this study is to statistically investigate and optimize the laser cladding process of Hastelloy X superalloy using NiCoCrAlY powder (Amdry 365). In this study, response surface methodology was used to investigate the influence of laser input variables such as scanning velocity, laser power, and duty cycle on the clad geometry (including height, width, and angle) and dilution ratio. The results indicate that with increasing duty cycle and laser power, the clad width increases significantly, while the clad height increases slowly. However, increasing the scanning velocity leads to a decrease in the width and height of the clad. Furthermore, the clad angle and dilution ratio increase with increasing input parameters. The results of variance analysis shows that laser scanning velocity had the most significant impact on clad height, angle and dilution ratio, while laser power had the greatest influence on clad width. The laser power of 321.3 W, the scanning velocity of 6.3 mm/s and the duty cycle of 76 % proved to be the optimal input parameters. An experimental test was carried out to validate the optimal conditions based on the optimization responses. The validation results show that the developed models are able to describe the responses with an accuracy of less than 9 % error. The EDS analysis performed in the cladding zone of the optimum specimen showed the presence of the β phase in the dendritic region and the γ phase in the interdendritic region.