Experimental characterizations of laser cladding of iron- and nickel-based alloy powders on carbon steel 1045 for remanufacturing

The purpose of this investigation is to test the laser cladding of different alloy powders onto 1045 medium-carbon steel substrates for parts remanufacturing. The types of alloy powder, laser output powers, and scanning speeds are selected as influencing factors to conduct laser cladding experiments with orthogonal design on the carbon steel 1045 substrate. Bonding shear strength and microhardness of the cladding layer and the substrate are tested and analyzed. The high resolution scanning electron microscopy and energy dispersive X-ray spectroscopy are also used to analyze cladding layers, microstructures, and elements. The experimental results show that a good metallurgical bond is formed between the cladding layer and the substrate without porous cracks and other defects. Shear stress intensity of nickel-based powder is two to three times higher than that of substrate material, while iron-based powder is five times higher than the substrate material. The type of the powder is the most significant factor and laser power is the least. The hardness of outer cladding layer is higher than that of bonding section and inner section. In the heat-affected zone, hardness is higher than that of the substrate material.