j m a t e r r e s t e c h n o l .

2 0 2 0;9(4):8258–8265

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Original Article

Parameters Optimization for Laser Cladding of

Inconel 625 on ASTM A592 Steel

Payman Shayanfar ∗ , Habib Daneshmanesh, Kamal Janghorban

Department of Materials Science and Engineering, School of Engineering, Shiraz University, Shiraz, Iran

a r t i c l e i n f o a b s t r a c t

Article history: In this study, Inconel 625 powder was deposited on ASTM A592 steel substrate using laser
Received 26 February 2020 cladding process. In order to optimize and predict the quality of the obtained coating,
Accepted 24 May 2020 empirical-statistical method was used and the linear relationship between the coating
Available online 9 June 2020 geometries for each sample (angle, width, height, depth of penetration and dilution) and
cladding parameters (power, powder feeding rate, and scanning rate) was obtained by the
use of regression method. Using these relationships, a process map has been extracted to
obtain the best quality for the cladding process. Hence, it is possible to obtain the optimal
parameters of coating geometry and the main laser parameters for the deposition of Inconel
625 powder on the ASTM A592 steel substrate with minimum porosity and without crack.
© 2020 The Authors. Published by Elsevier B.V. This is an open access article under the
CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

tivity of this steel to heat input is bolder when the dimensions

1. Introduction of the coated specimen is so small that even the use of arc coat-
ings such as GTAW and SMAW can result in a high heat input.
In this study, A592 steel which is a type of quench and temper
In such cases, the use of laser method is of higher importance
steel with a martensitic structure, has been used. The note-
[5,6].
worthy point about the coating of quench and tempered steels
On the other hand, A592 steel has various applications,
is their heat input. The reason for this is that high heat input
one of which is marine environments in which, considering
can result in cracking in the substrate [1,2]. The sensitivity of
the high corrosivity of sea water against this steel, there is
this kind of steel against heat input during coating and weld-
a need for a corrosion-resistant coating. Noting that Inconel
ing is so high that some welding methods such as ESW and
625 is highly resistant in corrosive environments, even at high
SAW are avoided for the case [2,3]. In order to minimize the
temperatures [7,8], for this purpose, Inconel 625 powder was
destructive effects of heat input during coating, and to avoid
used.
cracking, laser coating has been adopted in this work. Laser
In recent years, there have been several studies on metal
coating has a minimum heat input and a high cooling rate [4].
coating dissimilar metals by nickel-based alloys [9–14]. How-
This minimizes the number of cracks in A592 steel. The sensi-
ever, no scientific studies were found by the authors on coating
A592 steel by Inconel 625 powder using laser method. Based on
the results obtained by other researches, it has been revealed
∗
Corresponding author. that statistic relationships change with changing the material
E-mail: pay.shay@yahoo.com (P. Shayanfar). that is being used in the coating or the substrate, or both. As
https://doi.org/10.1016/j.jmrt.2020.05.094
2238-7854/© 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://
creativecommons.org/licenses/by-nc-nd/4.0/).
 j m a t e r r e s t e c h n o l . 2 0 2 0;9(4):8258–8265 8259

Table 1 – Chemical composition of clad powder and substrate materials.

Elements wt(%)
Material Form
Ni Cr C Co Mo S P Mn Al Si Nb Fe Other Elements

Inconel 625 Powder Rem 22 - 1 11.8 - - - 2 - 5 1.6 3<

ASTM A592 Plate - 0.57 0.15 - 0.24 0.025 0.025 0.83 - 0.46 - Rem 0.5<

previously mentioned, no studies were found on the coating

of Inconel 625 powder on A592 steel. Therefore, the presented
statistic model in this study can be considered as the first
statistic model ever on these materials.
In order to have an overlap coating with proper properties
such as good adhesion between the layers and between the
layers and the substrate, proper thickness, proper density and
being free from cracks, single-pass claddings should be of good
quality. Hence, the prediction of the properties of a single layer
coating is of great importance. In recent years, several physical
methods have been used for this purpose [15–20].
In this case, the empirical-statistical model can help
predict the properties of a single-pass cladding by determin-
ing the main parameters of the laser (F, V, P) and finding
its statistical relation with the geometry of the single-pass
cladding layer. Several studies have been conducted recently
on empirical-statistical models for different coatings and Fig. 1 – FESEM image of Inconel 625 powder.
substrates. By examining these results, it is clear that the sta-
tistical relationships change with the changes in the cladding,
substrate, or both of them [19,20].
P (w) were selected as the key parameters in such a way that
In this study, we have tried to obtain an empirical-
one parameter was appropriately increased while the remain-
statistical relation for the laser cladding of Inconel 625 powder
ing parameters were fixed.
on ASTM A592 steel substrate using a regression method, and
The substrate sample was grinded by emery paper (No.200).
a statistical model for predicting the properties of single-pass
The Laser Coating was carried out for 36 samples in single pass
cladding is proposed.
mode with an approximate length of 3 cm on both sides of the
The objective of this study is to develop a linear relation-
substrate sample. Then, the samples were cut into dimensions
ship between key laser parameters, power (P), powder feeding
of approximately (30*10*4)mm, and mounted with dimensions
rate (F) and scanning rate (V) and geometrical dimensions
of (40*40*10)mm. Next, they were polished and etched with a
of single-pass coatings (width, height, angle, depth of pene-
solution with equal parts of HCl, HNO3 , and CH3 COOH. After-
tration and dilution) with the purpose of optimizing the key
wards, they were imaged by scanning electron microscope
parameters of laser coating of Inconel 625 powder on ASTM
(FESEM; MIRA3; Czech Republic). Geometrical characteristics
A592 and avoiding numerous tests and wasting time. For this
and key laser parameters are presented in Table 2.
purpose, regression-analysis method was used.
Here, w is the width of the weld (mm), h is the height of the
cladding layer (mm), b is the depth of penetration relative to
the surface(mm), and ␪ is the wetting angle (Degree). In addi-
2. Materials and methods tion, geometrical dilution D (%) is obtained according to Eq.
(1).
In this study, ASTM A592 steel substrate with dimensions
of (100*60*100) mm was used as the substrate. Inconel 625 b
D% = (1)
powder made by Jiangwu boda Corporation with a particle h+b
size of (40–90) ␮m was used as the feedstock powder. The
chemical composition of Inconel 625 powder is represented 2.1. Statistical analysis
in Table 1 according to the manufacturer’s statement. The
morphology of the powder particles of Inconel 625 which is Three parameters have maximum effect on the coating qual-
obtained through FESEM microscope is shown in Fig. 1. ity in laser coating process and are considered to be among the
In this experiment, a pulsed YAG laser with a power of 700 main parameters of the process; namely, mean power or P (W),
W and a laser-beam diameter on the substrate of 1 mm was laser scanning speed or V (mm/s), and powder feeding rate or F
used. Argon was used as the protective gas with an injection (mg/s) [17–20]. When there is a relationship between the vari-
rate of 20 lit/min. Laser frequency and time were adjusted at ables, it can be expressed by mathematical patterns. Generally
35 Hz and 3 ms respectively. such a pattern can be linear or non-linear. If the interdepen-
The main parameters of the laser machine such as scan- dency pattern is put in a linear equation, it is called linear
ning rate V (m/s), powder feeding rate F (mg/s) and laser power regression equation. The aim of regression is to predict the
8260 j m a t e r r e s t e c h n o l . 2 0 2 0;9(4):8258–8265

Table 2 – Processing parameters and average of three measurements for each single clad.
Processing Parameters Geometrical Parameters

Track P(W) V(mm/s) F(mg/s) h(␮m) w(␮m) ␪◦ b(␮m) D%

1 150 3 100 85 ± 2 995 ± 4 10 ± 1 57 ± 2 40 ± 2
2 150 4 100 55 ± 1 895 ± 4 8±1 47 ± 1 46 ± 2
3 150 5 100 42 ± 1 885 ± 4 8±1 52 ± 2 55 ± 3
4 150 3 200 89 ± 2 1195 ± 5 13 ± 1 42 ± 1 32 ± 1
5 150 4 200 66 ± 1 1035 ± 5 11 ± 1 37 ± 1 36 ± 1
6 150 5 200 63 ± 1 1025 ± 5 11 ± 1 41 ± 1 39 ± 1
7 150 3 300 83 ± 2 1098 ± 5 16 ± 2 45 ± 1 35 ± 1
8 150 4 300 75 ± 2 965 ± 4 16 ± 2 44 ± 1 37 ± 1
9 150 5 300 62 ± 1 935 ± 4 14 ± 2 43 ± 1 41 ± 2
10 200 3 100 118 ± 3 1524 ± 5 11 ± 1 72 ± 3 38 ± 1
11 200 4 100 100 ± 2 1509 ± 5 9±1 76 ± 3 43 ± 2
12 200 5 100 63 ± 1 1474 ± 5 7±1 71 ± 3 53 ± 3
13 200 3 200 127 ± 3 1573 ± 5 17 ± 2 66 ± 2 34 ± 1
14 200 4 200 95 ± 2 1511 ± 5 15 ± 1 54 ± 2 36 ± 1
15 200 5 200 93 ± 2 1473 ± 5 11 ± 1 60 ± 3 39 ± 1
16 200 3 300 134 ± 3 1456 ± 5 21 ± 2 58 ± 2 30 ± 1
17 200 4 300 109 ± 2 1424 ± 5 15 ± 1 49 ± 1 31 ± 1
18 200 5 300 93 ± 2 1387 ± 4 14 ± 1 57 ± 2 38 ± 1
19 250 3 100 129 ± 3 1705 ± 5 11 ± 1 88 ± 3 40 ± 2
20 250 4 100 92 ± 2 1643 ± 5 8±1 93 ± 3 50 ± 3
21 250 5 100 60 ± 1 1552 ± 4 8±1 91 ± 3 60 ± 3
22 250 3 200 183 ± 3 1687 ± 5 16 ± 2 95 ± 3 34 ± 1
23 250 4 200 102 ± 2 1554 ± 5 13 ± 1 67 ± 2 40 ± 2
24 250 5 200 76 ± 1 1442 ± 5 11 ± 1 68 ± 2 47 ± 2
25 250 3 300 178 ± 3 1663 ± 5 20 ± 2 77 ± 2 30 ± 1
26 250 4 300 139 ± 3 1531 ± 5 15 ± 1 82 ± 3 37 ± 1
27 250 5 300 116 ± 2 1521 ± 5 14 ± 1 88 ± 3 43 ± 2
28 300 3 100 224 ± 4 1788 ± 6 11 ± 1 138 ± 4 38 ± 1
29 300 4 100 142 ± 3 1684 ± 5 10 ± 1 143 ± 4 50 ± 3
30 300 5 100 73 ± 1 1637 ± 5 13 ± 1 116 ± 4 61 ± 3
31 300 3 200 253 ± 4 1722 ± 6 14 ± 1 133 ± 4 34 ± 1
32 300 4 200 155 ± 3 1651 ± 5 13 ± 1 104 ± 3 40 ± 2
33 300 5 200 129 ± 3 1636 ± 5 11 ± 1 108 ± 3 45 ± 2
34 300 3 300 236 ± 4 1745 ± 6 18 ± 2 115 ± 3 32 ± 1
35 300 4 300 184 ± 3 1672 ± 5 17 ± 2 109 ± 3 37 ± 1
36 300 5 300 145 ± 3 1661 ± 5 13 ± 1 105 ± 3 42 ± 2

behavior of dependent variable (Y), which is the geometrical

dimension of the coating here, via the use of statistical sam-
ples and having the information of values and characteristics
of the independent variable (X). In simple linear regression, if
Y is the dependent variable and X is the independent one, the
regression linear equation can be written as follows [19]:

Y = aX + b (2)

The combination (P˛ .Sˇ .F ) can be assumed to be the inde- Fig. 2 – Schematic representation of geometrical
pendent variable (X). The regression linear equation is then characteristics in a single[20].
calculated by Eq. (3) [20]:

Y = a(P␣ .S␤ .F␥ ) + b (3)

In this equation, a and b are line parameters which can be
obtained by excel software. But for defining the powers ␣, ␤,
and ␥, MATLAB software was used. They are defined in such
a way that the optimum linear regression coefficient (R) is
reached between the dependent and independent variables.
As this coefficient gets closer to digit 1, the linear relationship
between combined parameters (P˛ .Sˇ .F ) and each of the geo-
metric dimensions of the single-pass coating (w, h, ␪, b and
D) becomes higher. Therefore, the linear equation related to
each geometric parameter can be extracted as a function of
the main parameters of the coating process. (Fig.2)
3. Discussion
Fig. 3 shows the transverse cross section of the claddings using
a Scanning Electron microscope. These claddings are arranged
in P, V and F according to Table 2. The geometric dimentions
 j m a t e r r e s t e c h n o l . 2 0 2 0;9(4):8258–8265 8261

Fig. 3 – Cross section optimal micrographs of the single clad tracks for different processing parameters. For each laser power
the scanning speed (V) increase from left to right and the power feeding rate (F) increases from up to down.

are also represented in Table 2. The geometric dimensions of

the claddings were measured by Digimizer software. As is also
shown in Scanning electron microscopy images, there are no
cracks in the coatings or the substrate metal.
The linear relationship between the height of the cladding
layer and the combined parameters of P, V and F is shown
in Fig. 4. The vertical axis represents the height and the hor-
izontal axis shows the combined parameters (P1/2 V-2 F2 ).
According to the diagram, the highest regression coefficient is
obtained as (R = 0.95). Using the combined parameters (P1/2 V-2
F2 ), one can obtain the highest value of (R) and the most appro-
priate relationship as in the diagram. Therefore, the h value
is a linear function of P, V, and F is the highest value which
is obtained at the lowest scanning rate. The lowest value of h
corresponds to the highest scanning rate.
In recent years, there has been a great deal of research Fig. 4 – Reliance of the clad height on the combined
regarding the effect of the combined parameters (F, V, P) on the parameter P1/2 V-2 F2 .
height of cladding layer [19–22]. In this study, a new empirical
model is proposed for laser cladding of Inconel 625 on ASTM
A592 steel substrate which introduces new coefficients for the the two parameters P and V on the height of the cladding
effect of combined parameters on the height of the cladding layer.
layer. However, a number of studies indicate the effect of The effect of laser beam power on the height of the cladding
layer can be explained by the fact that with higher laser power,
8262 j m a t e r r e s t e c h n o l . 2 0 2 0;9(4):8258–8265
Fig. 5 – Reliance of the clad width on the combined
parameter P1/2 V-1/5 .
the heat input is increased and a higher amount of pow-
der is melted and thereby the height of the cladding layer is
increased. In addition, the distribution of injected powder par-
ticles and the attenuation of the laser beam can also affect the
energy absorption during the cladding process [20].
Fig. 5 shows the linear relation of the width of the cladding
layers and the combined parameters (P.V) with the regression
coefficient of (R = 0.91). It is indicated in this diagram that the
powder injection rate does not affect the width of the cladding
layers. Therefore, the width of the claddings is obtained by the
combined parameter (P1/2 V-1/5 ). The combined (V, P) parame-
ter in this study is consistent with the combined parameters
of the past researches [16,23].
The laser beam forms a melt pool with the heat that it gen-
erates in the underlying layer. However, several factors can
affect the depth and width of the melt pool including the buoy-
ancy force, the shear stress induced by the surface tension
gradient (Marangoni convection) and the shear stress caused
by the plasma. In general, several physical parameters can
affect the width and depth of the weld pool. In this research,
other variables are assumed to be in equilibrium and only
two parameters of P and V are considered as the two effective
parameters [20–22].
Dilution is one of the important factors that can affect
the quality of the cladding. Dilution degree depends on the
height of the cladding (h) and the penetration depth of the
cladding layer (b). Dilution degree can be predicted by obtain-
ing a statistical relation between the penetration depth and
the combined parameters.
Fig. 6 shows the statistical relationship between penetra-
tion depth and combined parameters. It is observed that there
is a correlation between penetration depth and combined
parameters of (P3 V-1/2 F3/4 ) with regression coefficient of (R =
0.88), which implies a linear relationship between the penetra-
tion depth and F, V, and P parameters. Similar to the previous
research, the penetration depth in this study also depends on
(F,V,P) value [22,24].
According to the principles of laser cladding, the laser
energy beam is absorbed by the underlying powder. Assum-
ing that the powder injection rate and the scanning rate are
constant, increasing the laser power increases the penetra-
tion depth. In other words, if the laser power is constant,
Fig. 6 – Reliance of the penetration depth on the combined
parameter P3 V-1/2 F3/4 .
Fig. 7 – Reliance of the dilution on the combined parameter
P1/2 V2 F-3/4 .
by increasing the rate of powder injection or reducing the
scanning rate or increasing the ratio of injectable powder to
the length of the cladding layer (F/V), the penetration depth
decreases. As the ratio of (F/V) increases, the laser energy
absorption by the powder is increased and a lower amount
of laser energy is transmitted to the substrate, resulting in a
lower penetration depth [25].
As the statistical relationship between the heights of the
cladding and the penetration depth has been obtained, it is
possible to calculate the dilution dgree. Fig. 7 shows the statis-
tical relationship between dilution and combined parameters
as (F1/2 V2 P-3/4) . The regression coefficient is (R = 0.95) which
represents a linear relationship. As a result, using combined
parameters of (F, V, P), the degree of dilution can be predicted.
In previous studies, the dilution degree was predicted
based on the (F, V, P). parameters. However, laser power is less
effective on the degree of dilution in comparison with injec-
tion and scanning rates [26,27]. As indicated, dilution degree
is obtained by Eq. (1) and given that the laser power has been
present in both numerator and denominator of the equation,
the laser power was eliminated from the equation for simpli-
fication.
Fig. 8 shows the relationship between the wetting angle
and the combined parameters as (V-1 F3/4 ) with a regression
coefficient of R = 0.91 The minimum angle (8◦ ) at the maxi-
mum scanning rate and the lowest powder feeding rate, and
 j m a t e r r e s t e c h n o l . 2 0 2 0;9(4):8258–8265 8263

Table 3 – Predicted combined parameters representing

the best correlation with measured geometrical
characteristics of single clads.
Quantity (y) Combined R a b
Parameter
(x)

h (mm) P1/2 V-2 F2 0.95 5E-06 0.0415

w(mm) P1/2 V-1/5 0.91 0.1649 0.4293
b (mm) P3 V-1/2 F3/4 0.88 1E-09 0.0402
D% P1/2 V2 F-3/4 0.95 2.4762 27.702
␪ (◦ ) P-1 V3/4 0.91 0.5897 4.8084

Fig. 8 – Reliance of the wetting angle on the combined
parameter V-1 F3/4 .
the maximum angle (21◦ ) at the minimum scanning rate and
maximum powder feeding rate have been measured. The com-
bined parameters in this study are consistent with previous
researches [8,9]. However, some researches include the com-
bined parameters of (F, V, P) [21,28].
All of the combined parameters as well as regression coef-
ficients are obtained. Added to this, the coefficients related to
the linear relationship between the geometric dimensions of
the cladding layers and the combined parameters are given in
(Table 3). In order to obtain a high-density coating it is neces-
sary to have a dilution degree higher than (10%) and a wetting
angle lower than (80◦ ), and this combination confers the least
porosity [15,20].
Due to the fact that in laser cladding, the layers should
overlap, the parameters of (F, V, P) should be optimally con-
sidered so that the minimum porosity in the cladding layer is
obtained. When the overlap occurs, the final cladding layer
over the single-cladding layer is usually thicker in a range
of about 25–35% [20]. In addition, some of the laser energy
is used to remelt the previous cladding layer, which is why
in overlapped conditions, the dilution degree is less than
the single-pass mode. However, the reduction in dilution is
not always constant and changes with altering the cladding
powder and substrate [29,30]. According to the data obtained
from the single-pass laser cladding of Inconel 625 on ASTM
A592 steel substrate, which is obtained based on dimensional
characteristics of the claddings, a process map as a two dimen-
sional diagram can be prepared (Fig. 9). In this diagram, the
vertical axis is the laser power (P) and the horizontal axis is
the ratio of the powder injection rate to the length unit (F/V).
Given the relationship between the combined parameters
and the wetting angle (␪◦ ), another horizontal graph is required
to indicate the amount of the wetting angle. Wettability varies
in a range between the vertical line of 8◦ and the vertical line of
21◦ . The statistical relation between the cladding layer height
(h) and the combined parameters (P1/2 V-2 F2 ) is plotted as a
parabolic curve with sizes of (h(mm) = 0.05,0.1,0.2,0.3,0.4). The
statistical relation between the weld width and the combined
parameter (P1/2 V-1/5 ) is plotted as parabolic lines with sizes of
(w(mm) = 0.8,1,1.2,1.4,1.6,1.8).

Fig. 9 – P vs. F/V depiction of processing map for laser cladding of Inconel 625 powder on ASTM A592 steel.
8264 j m a t e r r e s t e c h n o l . 2 0 2 0;9(4):8258–8265
The lines corresponding to the statistical relation between
dilution and the combined parameters of (P1/2 V2 F-3/4 ) are
plotted having values of (35%) and (45%) in the map. The
desired dilution degree is considered between these two lines.
It is worth noting that the measured dimensional parameters
(w,h,b,D,␪) correspond to single pass cladding and cannot be
used for the overlapped mode. The shaded area on the map
has the lowest possible porosity, low dilution and good met-
allurgical boundary with the substrate. The height and width
of the cladded layer located in this area can be considered
as suitable for a cladding layer. This is the process map of the
deposition of Inconel 625 powder on the ASTM A592 steel sub-
strate which can be used as a guideline to select the optimum
laser parameters (F, V, P).
4. Conclusion
In this study, a statistical method was developed in order
to predict the geometrical dimensions of the single-pass
Inconel 625 model on A592 steel. This statistical model was
obtained by regression method based on the linear relation-
ship between the combined parameters (P˛ .Sˇ .F ) and the
geometrical dimensions of the coating (w, h, ␪, b and D). After
obtaining all of the linear equations and mixing them, the
process map was finally designed based on which single-pass
coating dimensions could be precisely predicted. By the use of
this process map which is composed of two parameters (F/V)
and P, the main laser parameters can be obtained in order to
achieve an optimum coating in a minimum possible time and
with suitable geometrical dimensions.
Conflict of interest
The authors declare that they have no known compet-
ing financial interests or personal relationships that could
have appeared to influence the work reported in this
paper.
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