Numerical simulation and analysis of surface

texture on the performance of die steel laser

cladding layer
changlong zhao 
(

zhao19790204@126.com
)
Mechanical and Vehicle Engineering
https://orcid.org/0000-0001-7778-3494
Zhenrong Ma 
Haifeng Zhang 
Chen Ma 
Junbao Yang 
Ming Li 

Research Article

Keywords: laser cladding, numerical simulation, surface texture, cladding temperature, residual stress

Posted Date: July 25th, 2022

DOI: https://doi.org/10.21203/rs.3.rs-1870467/v1

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Abstract
In order to reduce the stresses and cracks generated during the progress of laser cladding and improve
the fatigue resistance and service life of the die steel, a simulation study of residual stresses and surface
texture is attempted by changing the parameters of the cladding process. Different melting process
parameters (power, scanning speed, spot radius) are selected as laser melting simulation factors and the
residual stress is used as the main experimental index in this paper. Three-factor, three-level orthogonal
simulation experiments are conducted to determine the optimal melting parameters by performing signal-
to-noise ratio and extreme difference analysis on the experimental results. The cladding temperature and
residual stress distribution are compared between prefabricated texture and non-texture cladding
simulation under the optimal cladding parameters. The results of the optimal melting parameters are as
follows: laser power of 800 W, scanning speed of 20 mm/s, spot radius of 1 mm, and the minimum
residual stress of 360 MPa. In the melting simulation, the average residual stress of the prefabricated
clad layer is 149 MPa, which is about 58.56% lower than that of the nonwoven simulation. In addition, the
experimental results are in accordance with the simulated results and validate that the residual stresses
may be reduced by the prefabricated texture under the premise of ensuring the melting temperature,
which in turn can achieve the purpose of reducing the crack generation.

1. Introduction
Mold is an important tool in the field of material molding, which plays an irreplaceable role in the
manufacturing industry. Due to the complex manufacturing process of the mold, the processing
procedures, long production cycle, and the price of mold materials is often expensive, resulting in a very
high mold cost. And the mold is mostly in the complex and harsh working environment, resulting in
failure, scrap form more complicated. Industrial production consumes a lot of metal resources, and in the
face of the problem of depleting metal mineral resources, it is especially urgent to save metal resources
[1]. In this context, many researchers have been carried out on mold repair technology. Common
remanufacturing methods include EDM[2], arc overlay welding[3], thermal spraying[4] and laser cladding
technology [5–6], which is widely used because of the advantages of dense organization of the clad
layer, high bond strength, low dilution rate and small heat-affected zone.

Laser cladding technology uses a high energy density laser beam to melt metal powder, which is
metallurgically bonded to the substrate, thereby improving the hardness, corrosion resistance and fatigue
resistance of the part [7]. During the melting process, the material undergoes physicochemical changes
while its own temperature climbs sharply, which in turn generates large local gradient differences and
heterogeneous plastic strains, leading to the generation of residual stresses and changes in strength,
which affect the service life of the product. Therefore, the analysis of the melt pool temperature and
temperature field distribution of the material during laser cladding is also extremely relevant. In case of
high temperature gradient difference, there will be uneven layer height, large deviation in shape and size,
bubbles or cracks in the clad layer. At the microscopic level, the grain size of the clad layer is coarse,
which weakens the comprehensive mechanical properties of the product. The selection of process
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parameters, such as laser power, scanning speed and path, directly affects the melt pool temperature and
the temperature distribution of the workpiece. Laser cladding is a transient heating process in the actual
experimental process. It is not only difficult to implement online monitoring for temperature changes, but
also requires several experiments and consumes a lot of metal materials. In the actual experimental
process, laser cladding is a transient heating process, and it is not only difficult to implement online
monitoring for temperature changes, but also requires several experiments and conspires to consume a
lot of metallic materials. In recent years, finite element numerical simulation methods have been used by
a wide range of researchers to provide a better prediction of the heat deformation and residual stress
distribution of the workpiece. By establishing a finite element model to simulate the laser melting process,
it is feasible to monitor the changing state of the temperature field, melt pool size, dilution rate, analyze
their relationship with the laser melting process parameters and optimize the process parameters to
achieve the desired effect on the surface layer quality of the part, thus improving the efficiency and
reducing the energy consumption. Navid Nazemi [8] et al. selected different process parameters and used
finite element numerical simulations for the cladding of stainless steel P420 powder on mild steel
AISI1018 to analyze the microhardness and residual stresses of the clad layer by the distribution of the
temperature field, which led to the optimal craft parameters. Farahmand P [9] et al. developed a three-
dimensional transient uncoupled thermoelasticity model, simulated single and multi-layer cladding
processes, investigated the effect of temperature on residual stresses during the cladding process and
identified that the stresses generated at the clad-substrate junction and multi-layer lap are more
concentrated and prone to induce cracks. Huaming Liu [10] et al. constructed a half finite element model
to analyze the effects of process parameters on melt pool temperature and solidification rate, which
concluded that laser power and scanning speed have significant effects on the evolution of temperature
field and stress. He X [11] et al. established a three-dimensional numerical model to simulate the laser
cladding process of H13 die steel and analyzed the temperature field distribution and the evolution
process of tissue composition, taking into account the heat transfer, phase change and melt pool flow. h-
BNJ and SS316 composite coatings were added to the surface of SS316 substrate by fiber laser melting
by Vikas Kumar [12] et al. Examination of the surface morphology and microstructure of the composite
coatings revealed a good metallurgical bond between the molten layer and the substrate, taking into
account the heat exchange, phase change, melt pool flow and other factors to analyze the temperature
field distribution and the evolution process of tissue composition. Alireza Mostajeran [13] et al. examined
the melting of WC-FeAlpowder on 321 stainless steel substrate and mainly analyzed the effect of melting
parameters including laser power probe speed, powder coating rate on the coating properties. Grzegorz
Moskal [14] et al. worked on the melting of 962 powder on 625 nickel-based alloy and found that the
melting layer contained cracks and pores. However few reports have been published on the study of
reducing stresses and crack generation in laser cladding by changing the structure of the substrate-clad
connection.

ANSYS finite element simulation software is used in this paper to simulate three single-layer laser
cladding of H13 die steel. In the simulation process, the volume heat generation rate is used to load the
heat source, the temperature field distribution during the laser cladding process is analyzed, and the

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temperature field simulation results. As a load, the stress field distribution of the cladding layer is
calculated by indirect coupling and the laser cladding simulation under the same conditions is performed
by presetting the pit texture on the base model to solve the temperature field and stress field distribution
results. The two results were compared and analyzed to find a new laser cladding method that effectively
stress and cracks.

2. Orthogonal Simulation Experiment Design

This simulation experiment uses the orthogonal experiment method [15–17]to optimize the laser
cladding process and seek the optimal solution. Laser power, scanning speed, and spot radius are
selected as experimental factors. The width and depth of the molten pool and residual stress are the
experimental indicators. Residual stress is the main indicator. A three-factor three-level orthogonal
simulation experiment is designed. The three levels of laser power are 800W, 1000W, 1200W, the three
levels of scanning speed are 5mm/s, 10mm/s, and 20mm/s, and the three levels of spot radius are
0.5mm, 0.75mm, and 1mm. The design of the orthogonal experiment table is shown in Table 1.

Table 1
Orthogonal simulation table
Order Laser power Scanning speed Spot radius

(W) (mm/s) (mm)

1 800 5 0.5

2 800 10 0.75

3 800 20 1

4 1000 5 0.75

5 1000 10 1

6 1000 20 0.5

7 1200 5 1

8 1200 10 0.5

9 1200 20 0.75

3. Model Building
3.1 Material performance parameters

The laser cladding simulation process belongs to transient thermal analysis. The thermal physical
properties of the material, such as specific heat capacity and thermal conductivity, change with
temperature. The base material selected this time is H13 steel, and the cladding layer material is Ni60A

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alloy powder. The thermophysical property parameters of H13 steel and Ni60A alloy powder are
calculated based on the literature [18] and JMatPro software. And curve fitting of the mutation point data
according to the liquid phase line of the material shown in Fig. 1 and Fig. 2, which shows that the melting
point of H13 steel material is 1445°C and the melting point of Ni60A alloy powder is 1060°C. When the
node temperature of the clad layer is higher than the liquid phase line temperature (1370°C), it is judged
that the node belongs to the melt pool.

3.2 Model building

3.2.1 No-texture model establishment

In this article, three single-layer laser cladding for temperature field is simulated and stress field coupling
is analyzed. The built-in modeling module of ANSYS is used to establish the laser cladding finite element
model as shown in Figure 3. The laser cladding simulation model is a symmetrical model, and only half
of the symmetrical model needs to be established. The size of the matrix model is 50mm×25mm×20mm,
and the size of the cladding layer model is 50mm×6mm×0.5mm. The model grid is divided into local
refinement. The grid size of the matrix material is 0.001mm, and the size of the cladding layer material is
0.001mm. The mesh size is 0.0005mm, and the selected element type is solid70, which has three-way
heat conduction capability. The model meshing is shown in Figure 4.

3.2.2 Texture model establishment

The size of the texture model is kept the consistent with that of the model with non-textured model while
the distribution of texture on the upper surface of the substrate model is shown in Figure 5. The shape of
the texture is rectangular and the size is 0.8×0.8×0.5 mm. After the texture is preset, the texture is filled
with Ni60A alloy powder material and the cladding layer is established on the base model. The solid70
unit is still selected and the model is meshed by the method of local refining. The layer and its nearby
areas have texture, which is irregular, so the mesh is divided by unstructured mesh. The mesh size of the
cladding layer is 0.0005mm, and the mesh size of the rest area is 0.001mm. The grid division result of the
model is shown in Figure 6.

3.3 Heat source model and boundary conditions

The application of the heat source adopts the Gaussian heat source model, and the heat conduction
control equation [19]is:

Among them,  is the density; C is the specific heat capacity; v is the scanning speed; T is the
temperature; t is the time; k is the thermal conductivity.

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The convective heat transfer boundary condition is adopted in the finite element simulation process,
without considering the effect of thermal radiation on the simulated process, and the convective heat
transfer [20] is:   

In which, h is the convective heat transfer coefficient, taken as 20W/(m²-℃); TS is the temperature of the
solid surface; TB is the ambient temperature, taken as 25℃.

In addition, papers [21-23] investigated the effect of preheating temperature on the stress and strain
during laser cladding by building a finite element model and found that the substrate preheating has a
great influence on the residual stress. As the substrate preheating temperature increases, the residual
stress of both substrate and the cladding reduces. And preheating will make the residual stress
distribution more uniform. In this paper, the matrix material is preheated during the cladding simulation
process, and the preheating temperature is 300℃.

4. Analysis Of Orthogonal Simulation Experiment Results

4.1 Selecting process parameters
The laser cladding simulation path is S-shaped. The first path is from left to right, the second path is from
right to left, and the third path is from left to right. After the cladding simulation of a path is completed, it
will be cooled for 20s until complete three single-layer cladding simulation processes. The depth and
width of the molten pool, and the residual stress are selected as the experimental indicators in orthogonal
simulation experiment, which are shown in Table 2, and the residual stress of the connecting surface of
the middle channel matrix and the cladding layer are selected as the calculation result.

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 Table 2
Orthogonal simulation results
Laser Scanning Spot The depth of The width of Residual S/N
Power speed radius molten pool molten pool stress

(w) (mm/s) (mm) (mm) (mm) (MPa)

800 5 0.5 2.1 3.1 640 -56.12

800 10 0.75 1.2 2.4 530 -54.49

800 20 1 1.1 2.2 360 -51.13

1000 5 0.75 2 4.5 755 -57.56

1000 10 1 1.3 3.5 521 -54.34

1000 20 0.5 1.4 2.8 538 -54.62

1200 5 1 2.5 6 672 -56.55

1200 10 0.5 1.9 3.8 822 -58.30

1200 20 0.75 1.5 3 740 -57.38

The signal-to-noise ratio analysis method is used to analyze the residual stress results. The signal-to-
noise ratio describes the ratio of signal to noise in the electronic system. The larger signal-to-noise ratio
is, the stronger signal is. And the noise is smaller, and the error between the output value and the expected
value is smaller. After the orthogonal simulation experiment results are obtained, the simulation data is
analyzed through the signal-to-noise ratio analysis method to find out the stable and optimal cladding
parameters. The signal-to-noise ratio calculation formula [24] is as follows:

1 n (3)
S / N(η) = − 10log( n ∑ i = 1F i 2),

Among them, n is the number of simulation experiments, and Fi is the residual stress value of the i-th
simulation experiment.

According to analysis results in Table 2, the depth of the molten pool in each group of simulation
experiments has exceeded the thickness of the cladding layer, and the effect of cladding has been
achieved. And the minimum residual stress appears at the laser power of 800W and the scanning speed
of 20mm/s. Under the cladding condition of a spot radius of 1mm, the minimum residual stress value is
360MPa.

On the premise that the cladding layer reaches the necessary cladding temperature, this paper will select
the residual stress as the main experimental index for analysis. The range analysis results of the residual
stress are shown in Table 3. The Pj1 corresponding to the laser power in the table represents is the sum
of the signal-to-noise ratio of the residual stress value of the simulated experiment at level 1 (K = 800W).

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The signal-to-noise ratio values are − 56.12, -54.49, -51.13, so the Pj1 value is -161.74, and the residual
range analysis value is based on this. The method is calculated sequentially. Finally, the optimal
parameter combination is K1V3R3, that is, the laser power is 800W, the scanning speed is 20mm/s, the
spot radius is 1mm, and the minimum residual stress value is 360MPa, which can be seen from the range
analysis. The results are consistent with the results of orthogonal simulation experiments.

Table 3
Results of residual stress range analysis
Parameters Laser cladding K(W) Scanning speed V(mm/s) Spot radius

R(mm)

Pj1 -161.74 -170.23 -169.04

Pj2 -166.52 -167.13 -169.43

Pj3 -172.23 -163.13 -162.02

Optimal K1 V3 R3

Rj 10.49 7.10 7.41

Order K > R > V

In addition, among the three factors, the laser power has the most significant impact on the residual
stress, followed by the spot radius. And the least impact on the residual stress is the scanning speed.
Among the selected multi-factor process parameters, the laser power is a direct factor of how much
energy the melt pool obtains, which determines the laser energy density. When the selected laser power is
too high, a large amount of heat will be generated in the surface layer of the substrate. The temperature
gradient difference will be larger after the laser beam moving and the material will generate more tensile
stress due to plastic strain in the process of slow cooling, which will induce the cracking. At a certain
laser power, it is known that the spot center has the highest heat flow density according to the Gaussian
heat source formula whose temperature distribution decreases gradually with the increase of the radius.
The smaller the radius of the spot, the higher the temperature at its center, which also causes a high
temperature gradient and affects the melting effect. With respect to the scanning speed, an appropriate
increase in the scanning speed shortens the time that the laser beam is applied to the substrate surface.
The maximum temperature decreases and the temperature difference is smaller, which makes the
residual stresses tend to decrease. Therefore, the optimal process parameters were determined in terms
of laser power of 800W, scanning speed of 20mm/s, and spot radius of 1mm based on the above
orthogonal experimental results with the smaller residual stresses as the evaluation index.

4.2 Analysis of simulation results without texture

Under the optimal cladding conditions, complete three single-layer cladding simulation output
temperature field distributions are shown in Fig. 7. The starting point, midpoint and end point of the
connecting surface of each substrate and cladding layer are selected to study the temperature change of
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the cladding layer with time. The temperature field and the temperature changing curve of each node with
time are shown in Fig. 8.

It can be seen from Fig. 8 that the temperature of the node rises rapidly when it is about to reach each
node, and then the temperature drops rapidly. The maximum temperature of the node during the cladding
process reaches 2050 ℃ and the other nodes have reached the melting point of the material during the
cladding process.

The temperature field analysis result is used as the load, and the stress field is analyzed after the unit
type is converted. The output stress field distribution is shown in Fig. 9. The stress value of the cladding
layer is finally solved. The stress field of the connecting surface of the intermediate substrate and the
cladding layer is selected as the research object for analysis. And the stress curve is obtained and shown
in Fig. 10.

It can be seen from Fig. 9 that the maximum stress value is 2490 MPa and this maximum value appears
on the connecting surface between the substrate and the cladding layer at the end of the first pass. As
can be seen from Fig. 10. The maximum stress value in the middle channel is at the end of the cladding
layer, with a maximum value of 587.47 MPa. The stress value in the middle section of the clad layer
fluctuates from 325 to 400 MPa with less fluctuation and the average stress value is 360 MPa. The stress
value in the middle section of the clad layer fluctuates from 325 to 400 MPa with small fluctuations, and
the average stress value is 360 MPa.

4.3 Analysis of the influence of texture on laser cladding

4.3.1 Simulation result analysis
Under the optimal cladding conditions (laser power 800W, scanning speed 20mm/s, spot radius 1mm),
three single-layer texture cladding simulations are carried out with the same heat source model and
boundary conditions. The output temperature field distribution is shown in Fig. 11. The starting point,
midpoint and end point of the joint surface of each substrate and cladding layer were selected for the
research of temperature variation of the cladding layer with time and the curve of temperature variation
with time at each node is shown in Fig. 12.

It can be seen from Fig. 12 that the temperature change trend of each node is consistent with the non-
texture simulation change trend. The maximum temperature of the node during the cladding process
reaches 2150°C, and the temperature of the other nodes reaches the melting point of the material. The
temperature of the texture cladding simulation is preset. The difference between the field distribution and
the non-textured simulation temperature field distribution is not obvious.

The stress distribution output of the preset texture cladding simulation is shown in Fig. 13. The stress
field at the joint surface of the substrate and the cladding layer of the intermediate path is selected for the
analysis and the stress curve of the intermediate path along the path distribution is shown in Fig. 14.

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As can be seen from Fig. 13 that the maximum stress value is 1440 MPa, which is 42.17% lower than the
maximum stress value of 2490 MPa without texture. The maximum value is the same as the maximum
value for the non-textured simulation, which occurs at the end of the first pass on the substrate to
cladding interface. As can be seen from Fig. 14 that the maximum value of the middle path stress is
transferred to a place 10mm away from the end of the cladding layer, and the stress values at both ends
are 90 MPa and 61.6 MPa, respectively, compared with the simulation of non-textured cladding. The
stress values of 587.47MPa and 240.29MPa at both ends of the cladding layer are reduced by 84.68%
and 74.36% respectively. The stress value of the cladding layer fluctuates in the range of 61.6MPa to
247.59MPa, and the average stress value is 149MPa. Compared with the average stress value of non-
textured cladding simulation, the average stress value is reduced by about 58.56%.

5. Laser Cladding Processing Experiment

The cladding experiment adopts H13 steel as the base material and Ni60A alloy powder as the cladding
layer material. Under the optimal cladding conditions, the laser power is 800W, the scanning speed is
20mm/s, and the spot radius is 1mm. The same heat source model and the boundary conditions are non-
textured and textured cladding, and the residual stress value of the workpiece after the cladding is
measured for comparison. The residual stress measuring instrument is made by the Canadian PROTO
company and the model is iXRD residual stress analyzer. Measuring the residual stress, use an
electrolytic polishing device to peel off the surface of the sample and electrolytically polish. Set the
polishing electrolysis time to 20s, working voltage to 40V, and current to 2A. Then measure the residual
stress along the X direction (laser scanning direction). The experimental equipment and interface are
shown in Fig. 15.

After measurement, the maximum stress value with texture is 1280 MPa, which is 38.02% lower than the
maximum stress of 2065 MPa without texture. The maximum stress in the middle channel with texture is
transferred to a place 10mm away from the end of the cladding layer. The values are 126.52 MPa and
85.6 MPa, respectively. Compared with the stress values of 550.32 MPa and 220.19 MPa at both ends of
the non-textured cladding simulated cladding layer, the stress values are reduced by 77.01% and 61.13%,
respectively. The average stress value of the textured cladding layer is at 198 MPa, compared with the
average stress value 481.22 MPa in the non-textured cladding simulation. The average stress value is
reduced by about 49.35%. The change trend is similar to the simulation, which proves that the laser
cladding based on the surface of the textured material is effective in reducing residual stress.

6. Conclusions
In this paper the laser power (800W, 1000W, 1200W), the scanning speed (5mm/s, 10mm/s, 20mm/s)
and the spot radius (0.5mm, 0.75mm, 1mm) are selected as experimental factors. The residual stress is
taken as the experimental index design orthogonal in simulation experiments. The optimal cladding
parameters are determined through the signal-to-noise ratio and range analysis method. The optimal

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cladding parameters are as follows: the laser power is 800W, scanning speed is 20mm/s, spot radius is
1mm, and output average residual stress is 360MPa.

The results of range analysis show that the laser power has the most significant influence on the residual
stress, followed by the spot radius, and the scanning speed has the least influence on the residual stress.

A rectangular parallelepiped pit texture with a size of 0.8×0.8×0.5mm is preset on the surface of the base
mode, which is filled with Ni60A alloy powder for laser cladding simulation. The temperature and stress
distribution of the non-textured and the preset texture is compared and analyzed. And the analysis results
are as follows: the temperature field difference between the two simulations is not obvious, and the
temperature of each node in the simulation process can reach the melting point of the material, and the
cladding process is successfully completed. The average residual stress value of the preset texture
cladding simulation is 149 MPa, which is about 58.56% lower than the stress value of the non-textured
simulation. The change trend of the residual stress measured by the cladding experimental processing
laboratory is similar to that of the simulation.

Through the simulation, processing experiments and the above summary, it can be known that the pre-
texture on the surface reduces the residual stress to a large extent, reduces the generation of cracks, and
provides an effective new method for improving the stress state of the laser cladding layer.

Declarations
Funding: This project was funded by the Natural Science Foundation of the Science and Technology
Department of Jilin Province (20200201220JC), and Scientific research project of Changchun University
(ZKQ202010).

Conflicts of Interest: The authors declare no conflict of interest.

Author Contributions: Formal analysis, Methodology, Writing–original draft, Changlong Zhao; Software,

Data curation, Zhenrong Ma and Chen Ma; validation, Junbao Yang and Ming Li; investigation, Haifeng
Zhang. All authors have read and agreed to the published version of the manuscript.

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Figures

Figure 1
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Liquid phase diagram of H13 die steel              

Figure 2

Liquid phase diagram of Ni60 alloy powder  

Figure 3

Finite element model of laser cladding       

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Figure 4

Mesh division diagram of the mode

Figure 5

Matrix texture model diagram                             

Figure 6

Mesh division diagram of texture model

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Figure 7

Temperature distribution diagram          

Figure 8

Curve of node temperature over time

Figure 9

Stress distribution diagram         

Figure 10

Stress distribution curve of the middle cladding layer

Figure 11

Temperature distribution diagram          

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Figure 12

Curve of node temperature over time 

Figure 13

Stress distribution diagram         

Figure 14

Stress distribution curve of the middle cladding layer

Figure 15

Residual stress measurement chart: (a) iXRD Residual stress analyzer; (b) Electrolytic polishing device; (c)
Surface residual stress measurement results. 

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