Statistical analysis and optimization of processing parameters in high-power direct diode laser cladding

High-power direct diode laser (HPDDL) offers a wide laser beam with a top-hat intensity distribution, making it an ideal tool for large-area cladding. In this study, a systemic study on the HPDDL cladding process was carried out by depositing Fe-based powder on ASTM A36 steel substrate. The effects of input processing parameters (laser power, powder feeding rate, carrier-gas flow rate, and stand-off distance) on the output responses (powder catchment efficiency, clad height, and clad width) were analyzed. The experimental matrix was designed, and a quadratic regression model was developed using a response surface methodology (RSM). Based on the developed model tested by the analysis of variance (ANOVA) method, the relationship between the output responses and the processing parameters were analyzed and discussed. The optimal parameters were identified by the desirability function in order to maximize the powder catchment efficiency, clad height, and clad width.