Thesis Final

A Ph.D.
THESIS DEFENSE ON
“EXPERIMENTAL INVESTIGATION ON LASER
CLADDING OF FERROUS ALLOY USING CO2
LASER”
PRESENTED BY
SUBRATA MONDAL
School of Laser Science and Engineering

Jadavpur University, Kolkata-32
School of Laser Science & Engineering, Jadavpur University
Outlines of Presentation
INTRODUCTION TO LASER CLADDING PROCESS
DESIGN OF EXPERIMENT
EXPERIMENTAL PLAN, EXPERIMENTAL SET-UP
EXPERIMENTAL RESULTS AND ANALYSES
MULTIPLE REGRESSION ANALYSIS (MRA)
ANALYSIS OF VARIANCE (ANOVA)
OPTIMIZATION USING TAGUCHI METHOD
OPTIMIZATION USING GENETIC ALGORITHM
OPTIMIZATION THROUGH GREY TAGUCHI ANALYSIS
OPTIMIZATION THROUGH UTILITY THEORY COUPLED WITH TAGUCHI’S
. QUALITY LOSS FUNCTION
DEVELOPMENT OF ANN AND PNN MODELS
WEAR BEHAVIOR TEST
MICRO HARDNESS TEST
CORROSION TEST
CONCLUSIONS
FUTURE SCOPE OF WORK
School of Laser Science & Engineering, Jadavpur University
INTRODUCTION
 Laser cladding was first used by Gnanamuthu at Rockwell International
Corporation in Thousand Oaks of California in the late 1970’s
 The development of high-power gas lasers (e.g., CO2 lasers) in 1975
performed laser welding, cutting and metal hardening in that decade
 Laser is characterized by the properties of high power density,
monochromatic nature, high brightness and high degree of coherence
 Laser cladding results in deposition of a thin layer of material (e.g., metals
and ceramics) on to the surface of a selected material such as Nickel,
Chromium, Titanium, Cadmium, Copper using a laser as heat source
 The coating provides a durable, corrosion-resistant layer, and the core
material provides the load bearing capability. The resulting thickness of the
clad is typically from 50 µm to 2 mm in one step
 There are other coating deposition techniques available in industry namely
arc welding, thermal spraying, electroplating etc. Laser cladding is an
important technological method that allows the deposition of thin protective
coatings on substrates
School of Laser Science & Engineering, Jadavpur University 1
Laser Cladding Process - general features and applications
 Because of this high flexibility, laser machining provides a number of
advantages over the traditional machining processes
 Laser cladding is very often the fusion of an alloy layer to a substrate surface
with a minimum melting of the substrate. The deposited material can be
transferred to the substrate by several methods: powder injection (blown
powder method ), pre-placed powder on the substrate, or by wire feeding.
 Laser cladding is a very complex process, involving processing parameters are
laser power, beam spot size, beam scan speed, focal length, powder feed rate
and powder particles size etc.
 For example, in the coating applications, in addition to “laser cladding”,
researchers also use the terms “laser coating”, “laser powder deposition” or
“laser surfacing”. The laser cladding technique can produce a much better
coating, with minimal dilution, minimal distortion, and better surface quality.
 Although, laser cladding has the potential for utilization in different industrial
divisions for metallic coating, its application to metallic coating is limited due
to the high cost and the low process speed.

Fig.1: A photographic view of a
CO2 laser cladding system showing
the melting of cladding material
and depositing it on the substrate
Fig.2: A sectional view of laser

cladding zone

Fishbone Diagram of Laser Cladding Process

Motion control
system
Nozzle
Laser system
Vertical motion
stage
Focusing optics
Powder feeder
X-Y motion
Deposition Control stages
Fig. 3:A typical laser cladding system
DESIGN OF EXPERIMENT
Determine the factors
Identify test conditions
Identify control and noise factors
Define the data analysis procedure
Design the matrix experiment (OAs)
Conduct designed experiments
Analyze the data

(software)
Predict the performance
Individual Relative Determination ANOVA and Performance

factor factor of optimum S/N analysis under optimal
contribution interaction levels for conditions
Validation Experiment

EXPERIMENTAL PLAN, SET UP AND PROCEDURE
Table 1: Control Factors & their Table 2: Experimental Layout using L9 OA

Levels
Trial Process Parameter’s Level
Levels Runs
Control Laser Scan Powder
Factors Power Speed Feed
1 2 3 Rate
Laser Power 0.3 0.5 0.8 1 1 1 1
(kW) 2 1 2 2
Scan Speed 0.3 0.5 0.8 3 1 3 3
(m/min) 4 2 1 3
Powder Feed 5 8 11 5 2 2 1
Rate (g/min) 6 2 3 2
7 3 1 2
8 3 2 3
9 3 3 1

PM POWDER
LASER BEAM FEEDER
CM
PM
PM
X-Y WORK STATION ARGON GAS
Fig.4: THE SCHEMATIC ARRANGEMENT

OF EXPERIMENTAL SET UP
EXPERIMENMTAL RESULTS AND ANALYSES
Table 3: 20Mn Cr5 steel sample Table 4: Mild steel sample
Expt. Clad height Clad width Clad depth Expt. Clad height Clad width Clad depth
Number (mm) (mm) (mm) Number (mm) (mm) (mm)

Avg. Avg. Avg. Avg. Avg. Avg.
0.393 0.942 0.63 0.182 4.12 0.52
1 0.391 0.392 0.941 0.941 0.63 0.62 1 0.184 0.183 4.11 4.11 0.0.51 0.51
0.392 0.94 0.61 0.183 4.12 0.51
0.342 0.882 0.57 0.234 3.71 0.41
2 0.341 0.341 0.881 0.882 0.59 0.58 2 0.233 0.233 3.72 3.72 0.40 0.41
0.342 0.883 0.58 0.234 3.73 0.42
0.474 0.992 0.54 0.223 3.394 0.33
3 0.473 0.473 0.993 0.992 0.52 0.53 3 0.235 0.223 3.393 3.393 0.31 0.32
0.473 0.991 0.53 0.234 3.392 0.31
0.813 1.213 0.64 0.134 2.573 0.24
4 0.812 0.812 1.212 1.212 0.63 0.63 4 0.133 0.133 2.574 2.573 0.25 0.25
0.813 1.211 0.63 0.132 2.572 0.26
0.412 0.971 0.84 0.251 4.254 0.53
5 0.411 0.411 0.972 0.972 0.83 0.83 5 0.252 0.251 4.252 4.253 0.51 0.52
0.412 0.973 0.82 0.251 4.253 0.52
0.163 0.751 0.43 0.19 3.686 0.26
6 0.161 0.162 0.753 0.752 0.42 0.42 6 0.191 0.191 3.687 3.687 0.25 0.25
0.162 0.752 0.42 0.192 3.688 0.25
1.254 1.992 0.36 0.178 4.2 0.26
7 1.253 1.253 1.991 1.991 0.37 0.37 7 0.177 0.177 4.19 4.19 0.25 0.25
1.252 1.99 0.39 0.175 4.18 0.24
0.242 1.13 0.56 0.296 4.638 0.39
8 0.241 0.241 1.11 1.12 0.55 0.55 8 0.298 0.297 4.637 4.637 0.38 0.38
0.241 1.12 0.54 0.297 4.636 0.37
0.242 0.922 0.76 0.362 4.75 0.52
9 0.243 0.242 0.921 0.921 0.75 0.75 9 0.363 0.363 4.74 4.74 0.51 0.51
0.241 0.921 0.74 0.364 4.73 0.51

Fig. (a): 5 Single clad beads Fig.(c): A single layer (50 %
overlapped bead)
Fig. 5: The photographic views of single clad

bead and single clad layer formed on 20Mn Cr5
steel substrate using Inconel-625 powder as
cladding material
Fig.(b): 4 single clad beads

Fig. (a):9 Single clad beads
Fig. (d): Double clad layer of cross tracks
Fig. (b): Double clad layer of Parallel tracks

Fig. (e): Double clad layer of cross tracks
Fig. 6: The photographic views of
single clad bead and clad layer
formed on mild steel substrate
using the mixture of Nickel,
Chromium and Molybdenum
Fig. (c): Double clad layer of Cross tracks powder as cladding material
Clad Fig. 7: Combined effect of Laser Power
Height and Scan Speed on Clad Height
(mm)
0.41
0.81
0.21
0.61
Scan speed Laser

(m/min) power (kW)
Clad Fig. 8: Combined effect of Powder Feed

Height rate and Laser Power on Clad Height
(mm)
0.45
0.46 0.29 0.62
Powder Laser
feed rate (g/min) power (kW)

Clad
Fig.9: Combined effect of Powder Feed
Height rate and Scan Speed on Clad Height
(mm)
0.74 0.55 0.36 0.17
Powder Scan speed

feed rate (g/min) (m/min)
Clad Fig.10: Combined effect of Scan Speed

Width and Laser Power on Clad Width
(mm)
1.15 1.4 0.15

0.94
Scan speed Laser
(m/min) power (kW)

Clad Fig.11:Combined effect of Powder Feed
Width rate and Laser Power on Clad Width
(mm)
1.1
1.0
0.93
Powder Laser
Fig.12: Combined effect of Powder Feed

Clad
Width rate and Scan Speed on Clad Width
(mm)
1.05
1.13
Powder Scan speed

Clad
Fig.13: Combined effect of Laser
Depth Power and Scan Speed on Clad Depth
(mm)
0.38 0.41
0.31
Scan speed 0.24 Laser
(m/min) power (kW)
Fig. 14: Combined effect of Laser Power

Clad
and Powder Feed rate on Clad Depth
Depth
(mm)
0.53
0.41
0.27 0.22 0.24
0.21
Powder Laser

Fig15: Combined effect of Powder
Clad
Depth Feed rate and Scan Speed on Clad
(mm) Depth
0.48
0.25 0.11
0.29
0.15
Powder Scan speed
Fig16: Combined effect of Laser Power

Deposition Rate x and Scan Speed on Deposition Rate
103(mm3/min)
0.29 0.41 0.51 0.61

0.19
Scan speed Laser

(m/min) power (kW)

Fig.17: Combined effect of Laser
Deposition Rate Power and Powder Feed rate on
x 103
(mm3/min) Deposition Rate
0.21 0.310.41 0.51

0.21
0.11
Powder Laser
Fig.18: Combined effect of Powder

Deposition Rate
Feed rate and Scan Speed on
x 103 Deposition Rate
(mm3/min)
0.25 0.21
0.21
0.15
Powder Scan speed

MULTIPLE REGRESSION ANALYSIS (MRA)
Let,
Where, Y = Response (Clad height - H or clad width - W or Deposition rate -
Dr ), K, a, b, c are constants, P = Laser power (kW), V = Scan speed
(mm/min), C = Powder mass flow rate (g/min)
Finally, the following equations are obtained in the context of cladding on
20Mn Cr5 steel using Inconel-625 as cladding material [Eqn. (1) – Eqn. (3)]
and same for mild steel using Ni-Cr-Mo as cladding material [Eqn. (4) – Eqn.
(6)].
(1),
(2),
(3),
(4),
(5),
(6),

ANALYSIS OF VARIANCE (ANOVA)
 It is performed to identify which process parameters are statistically
significant.
 In this analysis, the parameters such as sum of squares (SS), mean square
(MS), degree of freedom (DF) and Fisher’s ratio (F) are calculated using
MINITAB software of version 13.
 A value of F less than one means the factor effect is smaller than the error of
the additive model. A value of F larger than two means the factor influence is
not quite small, whereas larger than four means the factor effect is quite large.
 It is seen that, for 20Mn Cr5 steel the most significant parameter for clad
height and clad depth is scan speed followed by powder feed rate and laser
power .
 The results are almost similar for mild steel substrates also.

OPTIMIZATION OF LASER CLADDING PROCESS
USING TAGUCHI METHOD
The major steps of implementing the Taguchi method are: (i) to identify the
factors/interactions, (ii) to identify the levels of each factor, (iii) to select an
appropriate orthogonal array (OA), (iv) to assign the factors/interactions to
columns of the OA, (v) to conduct the experiments, (vi) to analyze the data
and determine the optimal levels, and (vii) to conduct the confirmation
experiment
‘larger-is-better’
‘smaller-is-better’
‘nominal value-is-best’

Fig.19: Response diagram of S/N
ratio for Clad Height (20Mn Cr5
steel)
Laser power (kW) Scan speed (m/min) Powder feed rate (g/min)

ratio for Clad Width (20Mn Cr5
steel)

ratio for Clad Depth (20Mn Cr5
steel)

Fig.22: Response diagram of
S/N ratio for clad height (mild
steel)
Fig.23: Response diagram of

S/N ratio for clad width (mild
steel)

ratio for clad depth (mild steel)

Table 3: Taguchi-optimized results and Validation (20Mn Cr5 steel)
Experimental Optimized APE
Responses Optimum Condition
Value Value (in %)
P = 1.00 kW (P1)
Clad height (H) V= 0.80 m/min (V3) 0.20 mm 0.18 mm 10.00
C = 5.00 g/min (C1)
P = 1.50 kW (P3)
Clad width (W) V= 0.30 m/min (V1) 1.97 mm 1.66 mm 15.74
C = 11.0 g/min (C3)
P = 1.50 kW (P3)
Clad depth (D) V = 0.80 m/min (V3) 0.21 mm 0.23 mm 9.52
C = 5.00 g/min (C1)
Table 4: Taguchi-optimized results and Validation (mild steel)

Experimental Optimized APE
Responses Optimum Condition
Value Value (in %)
P = 1.50 kW (P3)
Clad height (H) V= 0.30 m/min (V1) 0.364 mm 0.375 mm 4.67
C = 11.0 g/min (C3)
P = 1.50 kW (P3)
Clad width (W) V= 0.30 m/min (V1) 4.74 mm 3.88 mm 2.95
C=11.00 g/min (C3)
P = 1.25 kW (P2)
Clad depth (D) V = 0.30 m/min (V1) 0.38 mm 0.35 mm 7.89
C = 8.00 g/min (C2)
OPTIMIZATION USING GENETIC ALGORITHM
 In the present context, single objective real coded genetic algorithm for
optimizing the laser power, scan speed and powder feed rate has been used.
The optimization has been done twice: once for minimizing the clad height,
clad depth and once for maximizing the clad width. To carry out this
optimization method the experimental data of Table 3.1 (for 20Mn Cr5 steel)
and Table 3.2 (for mild steel) have been used while utilizing MATLAB® -
7.0 software.
 The initial population in both cases was a set of randomly generated real
numbers in the given range. The maximum number of chromosomes in the
population has been fixed to be 100. Each chromosome size is three numbers
long - one number for each of the laser power, scan speed and powder feed
rate.
 The Equations (3.9) – (3.14), developed by multiple regression analysis in
Chapter 3 have been used as the objective functions for minimizing clad
height, clad depth and maximizing clad width.

Table 5: GA optimized results and Validation (20Mn Cr5 steel)
Optimum Experimental Optimized
Responses APE (in %)
Condition Value Value
A = 1.23 kW
Clad Height B = 0.62 m/min
0.121 mm 0.0951 mm 7.17
(H) C = 5.35 g/min
A = 1.49 kW
Clad Width B = 0.31 m/min
2.124 mm 1.971 mm 7.66
(W) C =10.97g/min
A = 1.19 kW
Clad Depth B = 0.41m/min
0.201 mm 0.112 mm 4.42
(D) C= 8.32 g/min
Table 6: GA optimized results and Validation (mild steel)

Optimum Experimental Optimized
Responses APE (in %)
A = 1.35 kW
Clad Height B = 0.45 m/min
0.175 mm 0.145 mm 17.14
(H) C = 7.25 g/min
A = 1.25 kW
Clad Width B = 0.38m/min
3.75 mm 4.651 mm 24.03
(W) C = 8.35 g/min
A = 1.15 kW
Clad Depth B = 0.55m/min
0.41 mm 0.352 mm 14.14
(D) C = 9.52 g/min

OPTIMIZATION THROUGH GREY TAGUCHI ANALYSIS IN CASE OF
CLADDING OF 20Mn Cr5 STEEL AND MILD STEEL
 Using grey relational (rather grey-Taguchi) methodology, multi-
objective optimization is made. Here, all the responses (clad height, clad
width and clad depth) are optimized combinedly. The grey relational
analysis (GRA) is a quantitative analysis to explore the similarity and
dissimilarity among factors.
 In the GRA the first step is to perform the normalization of
experimental data to make them lie within the range of 0 to1.
 The GRG also expresses the deviation between the experimental value
and the ideal value. According to importance of quality characteristics,
there are three criteria for optimization in grey relational analysis, which
are ‘larger-is-better’, ‘smaller-is-better’ and ‘nominal-is-best’.
 In the present analysis higher value of clad width indicates better
cladding performance, therefore a ‘larger-is-better’ criterion is chosen for
clad width. On the other hand, lower value of clad height and clad depth
represent better cladding performance, therefore ‘smaller-is-better’ is
chosen for them.
‘larger-is-better’
‘smaller-is-better’
‘nominal-is-best’
where, Xij represents the normalized value of jth response

at ith number of experiment, Yij represents the actual value
of jth response at ith number of experiment and OB
represents target value.

• Grey Relational Coefficient
Where ; , = Reference data or best data

and represents the normalized value of jth response at ith
number of experiment.
= maximum value of and
= minimum value of and
ξ = the distinguishing or identification coefficient, and its
value lies between 0 and 1. Usually, it is assumed at 0.5 to
fit the practical requirements
• Grey Relational Grade
where, Wj = weighting factor for jth
response

Table 7: Grey relational coefficients and grades (20Mn Cr 5 steel)
Grey relational
Normalized data Grey relational coefficient
grade
Sl.
Clad Clad Clad Clad Clad Clad
No.
height width depth height width depth Value Order
(H) (W) (D) (H) (W) (D)
1 0.21082 0.15254 0.54348 0.38784 0.37107 0.52273 0.42159 5
2 0.16407 0.10492 0.45652 0.37427 0.35840 0.47917 0.39939 8
3 0.28506 0.19370 0.34782 0.41154 0.38276 0.43396 0.40676 6
4 0.59578 0.37127 0.56522 0.55297 0.44297 0.53488 0.50354 3
5 0.22823 0.17756 1 0.39315 0.37809 1 0.56918 2
6 0 0 0.10869 0.33333 0.33333 0.35938 0.34115 9
7 1 1 0 1 1 0.33333 0.8 1
8 0.07241 0.29701 0.39130 0.35024 0.41563 0.45098 0.40662 7
9 0.07333 0.13640 0.82609 0.35047 0.36668 0.74194 0.47439 4
Table 8: Grey relational coefficients and grades (mild steel)

Grey relational
Normalized data Grey relational coefficient
grade
Sl.
Clad Clad Clad Clad Clad Clad
No.
height width depth height width depth Value Order
(H) (W) (D) (H) (W) (D)
1 0.78261 0.24769 0.4 0.47136 0.39926 0.68888 0.50778 5
2 1 0.06615 1 0.33896 0.34871 0.30693 0.33325 9
3 0.81159 0.37846 0.71428 0.44803 0.44581 0.50819 0.46519 8
4 0.56522 0 0.85714 0.77352 0.33333 0.38271 0.48020 6
5 0.28985 0.77538 0 0.58017 0.69002 0.30693 0.54214 4
6 0.75362 0.51384 0.85714 0.49727 0.50702 0.38271 0.46681 7
7 0.60869 0.74615 0.85714 0.68562 0.66326 0.38271 0.58581 3
8 0.48840 0.95230 0.5 1 0.91292 1 0.96517 1
9 0 1 0.05714 0.35354 1 0.33333 0.60606 2

Table 9: Validation of the Grey-Taguchi method optimized results (20Mn Cr 5 steel)
Optimal cladding parameters
Initial cladding
parameters Experiment Prediction
Setting Level
Clad Height (mm) 0.392 0.34
Clad Width (mm) 0.941 1.22
Clad Depth (mm) 0.62 0.34
Table 10: Grey
Validation of the Grey-Taguchi
relational grade 0.421599 method
0.421893 optimized 0.6204
results (mild steel)
Optimal cladding parameters
Initial cladding
parameters Experiment Prediction
Setting Level
Clad Height (mm) 0.18333 0.21333
Clad Width (mm) 3.11 4.2512
Clad Depth (mm) 0.41 0.223
Grey relational grade 0.50778 0.56163 0.70212

OPTIMIZATION THROUGH UTILITY THEORY COUPLED WITH
TAGUCHI’S QUALITY LOSS FUNCTION IN CASE OF
CLADDING ON MILD STEEL SPECIMEN
The Overall Utility function
The Overall Utility function after assigning weight
is the weighting factor assigned to the attribute i
The preference number, Here, is the value of any quality

characteristic or attribute at ith number of
experiment, is the just acceptable value of
quality characteristic or attribute i and is a
constant.

where is the optimal or best value
The overall utility value can be calculated as follows
subject to the condition,
Thus, the overall utility index serves as single objective

function for optimization

Table 11: Utility values of individual response (20Mn Cr5 steel)
Sl. No. H W D
1 5.396 0.7157 2.7199
2 6.428 0 1.2058
3 4.0039 1.2992 0.84097
4 0 3.5132 3.083
5 5.045 1.074 9.343
6 11.943 1.7623 6.1223
7 3.214 9 9
8 9 2.641 0
9 8.969 0.4783 7.0416
Table 12: Utility values of individual response (mild steel)

Sl. No. H W D
1 3.837 3.181 2.544
2 9 1.21 9
3 4.437 4.451 2.4791
4 0 0 5.4113
5 3.964 7.7426 7.269
6 3.258 5.6594 5.4113
7 0.63381 7.524 5.4113
8 1.255 9 0
9 7.251 9 6.6733

Table 13: Overall Utility Index and S/N ratios (20Mn Cr5 steel)
Sl. No. Overall Utility Index S/N ratio Order of Experiment
1 2.72105 8.69473 6
2 2.29026 7.197696 8
3 1.973141 5.903162 9
4 2.33018 7.347789 7
5 4.74597 13.5265 4
6 6.12451 15.74143 2
7 7.2642 17.22376 1
8 3.7564 11.49544 5
9 4.9945 13.96984 3
Table 14: Overall Utility Index and S/N ratios (mild steel)
Sl. No. Overall Utility Index S/N ratio Order of Experiment
1 3.1867 10.06682 8
2 5.884 15.39345 3
3 3.85523 11.72101 7
4 1.62339 4.208457 9
5 6.46694 16.21398 2
6 4.86455 13.74085 4
7 4.823133 13.66658 5
8 3.9765 11.99002 6
9 7.77729 17.81657 1

DEVELOPMENT OF ANN AND PNN MODELS
 The aim of this chapter is to realize ways to evaluate accomplishment
and performance of neural network in modeling of laser cladding process.
 In this chapter, architecture of neural network for prediction of clad bead
feature i.e. laser clad height, clad width and clad depth in laser cladding
process is presented.
 In the present work, it is difficult to run the ANN program in
MATLAB®-7.0 software with less number of data, therefore some more
artificial data have been generated using linear regression equations .
 All the ANN and PNN algorithms have been developed using MATLAB
coding
 In this work clad height (H), clad width (W) and clad depth (D) are
considered as performance characteristics
 The results obtained from artificial neural network (i.e. BP-MLP) and
probabilistic neural network have been compared with respect to multiple
regression analysis
P
V H/W/p
C Fig.22: Structure of 4 layered BP-MLP
model (20Mn Cr5 steel)
Input Layer Output Layer
Hidden Layers
P Fig.23: Structure of 4 layered BP-MLP

V H/W/p
C model (mild steel)
Input Layer Output Layer

Hidden Layers

Fig.24: Variation of total error with
number of Epochs in 3-7-9-1 network
(20Mn Cr 5 steel)
Fig.25: Variation of total error with number

of Epochs in 3-4-9-1 network (mild steel)

Fig.26: Comparison among BP-MLP, PNN
and experimental plots for clad height
(20Mn Cr5 steel)
Experiment number
Fig.27: Comparison among BP-MLP, PNN

and experimental plots for clad width (20Mn
Cr5 steel)
Experiment number

Fig.28: Comparison among BP-MLP,
PNN and experimental plots for clad
depth (20Mn Cr5 steel)
Experiment number
Fig.29: Comparison among BP-MLP,

PNN and experimental plots for clad
height (mild steel)
Experiment number

Fig.30: Comparison among BP-
MLP, PNN and experimental plots
for clad width (mild steel)
Experiment number
Fig.31: Comparison among BP-

MLP, PNN and experimental
plots for clad depth (mild steel)
Experiment number

Table 15: Validation of the ANN predicted results (20Mn Cr5 steel)
Responses Optimum Experimental Predicted APE (in

Condition Value Value %)
Clad Height
A1B3C1 0.20 mm 0.22 mm 10.0
(H)
Clad Width
A3B1C3 1.97 mm 2.12 mm 7.6
(W)
Clad Depth
A3B3C1 0.21 mm 0.19 mm 9.5
(D)
Table 16: Validation of the ANN predicted results (mild steel)
Responses Optimum Experimental Predicted APE (in %)

Clad Height
A3B1C3 0.364 mm 0.324 mm 10.98
(H)
Clad Width
A3B1C3 4.74 mm 3.997 mm 15.67
(W)
Clad Depth
A2B1C2 0.38 mm 0.327 mm 13.94
(D)

Wear Behavior Test
Base Sample (without cladding)
Fig.32: 20Mn Cr5 steel substrate coated
by Inconel-625 (For the sample shown in
Fig. 5 (b))
Cladded Sample
Time (Second)
1-Base sample
2-Double coated layer, made parallel (For the
sample shown in Fig. 6 (b))
3-Double coated layer, made cross wise (For the Fig.33: Mild steel substrate
sample shown in Fig. 6 (c)) coated with Ni-Cr-Mo powder
mixture
1
2
3
Time (Second)
Micro Hardness Test
Fig.34: Results of micro hardness test of the
20Mn Cr5 steel laser cladded with Inconel-625,
measurement being made along the depth from
the top of the clad surface
Depth (mm)
Fig. 35: Results of micro hardness test of the

mild steel laser cladded with mixture of
nickel, chromium and molybdenum,
measurement being made along the depth
from the top of the clad surface. ‘ ’ For
double cladded parallel tracks, ‘ ’ double
cladded cross tracks
Depth (mm)
Table 17: Corrosion result of Base Specimen and Inconel-625 cladded on 20Mn Cr5
steel substrate
Corrosion Corrosion
Corrosion in
Sl. Scan rate Current, Voltage, Corrosion rate
3.56% NaCl
No. (mm/s) Icorr (x10-5 Ecorr. (mV) (mm/year)
solution
A/mm2)
Base
1 5 4.659 -915 2.06
Specimen
Coated
2 5 1.382 -851 0.616
Specimen
Table 18: Corrosion result of Base Specimen and nickel, chromium and
molybdenum mixed coated on mild steel substrate
Corrosion in Corrosion Corrosion
Sl. Scan rate Corrosion rate
3.56% NaCl Current, Icorr. Voltage,
No. (mm/s) (mm/year)
solution (x 10-5 A/mm2) Ecorr. (mV)
1 Base Sample 5 0.3383 -930 2.896

Double Coated
2 Sample 5 0.07073 -756 0.848
(Parallel wise)
Double Coated
3 Sample (Cross 5 0.1586 -906 1.901
wise)

(a) (b)
Fig.36: SEM photographs of laser clad-substrate interface (single track) with Clad
material: Inconel-625, Substrate: 20Mn Cr5 steel; (a) P=1.25 kW, V=0.5 m/min, C= 5
g/min. (b) P=1 kW, V=0.5 m/min, C= 8 g/min
(a) (b)
Fig.37: SEM photographs of laser clad-substrate interface (single track) with Clad
material: Inconel-625, Substrate: 20Mn Cr5 steel; (a) P = 1.5 kW, V = 0.3 m/min, C = 11
g/min. (b) P =1.5 kW, V = 0.3 m/min, C = 11 g/min

Mounted material
Clad layer
Substrate
Fig.38 A microscopic view of Inconel-625 coating on 20Mn Cr5 steel

(For the sample shown in Fig. 5(b))
It is seen that the bottom face of the clad beads is uniform

in width and depth; its contour profile is of round shape.

CONCLUSIONS
Based on the above experiments and investigations the following conclusions are
drawn
 Experiments performed on laser cladding with nickel based powder as coating
material on a substrate of ferrous alloys, showed that this method is suitable for
obtaining single or multiple clad tracks.
 The selected process control parameters of laser cladding process in the present
work have been laser power, scan speed of work table and powder mass flow rate.
It is found that each parameter has significant influence on clad bead quality.
 The effects of process parameters on the responses have been studied by
ANOVA. From ANOVA analysis it is found that for clad height and clad depth of
20Mn Cr5 samples, the most significant factor is scan speed, followed by powder
feed rate and laser power. For clad width, the most significant parameter is also
scan speed, followed by laser power and powder feed rate. In case of mild steel
samples, almost same observations are made.
 The multiple regression analysis has correlated the process parameters with the
responses. The developed relationships have been applied in ANN modeling to
generate the artificial data. The results of multi regression analysis confirm well to
the observed data.
 The multiple regression analysis has correlated the process parameters with
the responses. The developed relationships have been applied in ANN
modeling to generate the artificial data. The results of multi regression analysis
confirm well to the observed data.
 In the present work, two single-objective optimization and two multi-objective
optimization techniques have been applied in order to optimize the laser
cladding parameters. Each optimization result has been validated by
performing a confirmation test. In case of single-objective optimization,
Taguchi method is found to be better for mild steel specimen and GA method
is better for 20Mn Cr5 steel specimen. On the other hand, for multi-objective
optimization, grey Taguchi optimization method is better for both the
specimens, as compared to utility based Taguchi method.
 The ANN model has been developed based on experimental results to predict
the clad bead features namely clad height, clad width and clad depth within the
experimental domain.

 The developed neural network algorithm could be applied to predict the clad
bead feature for any combination of the values of the process parameters (within
the experimental domain) other than optimum setting of the process parameters, as
well.
 The micro hardness test shows that the maximum hardness is obtained at clad
layer (170 VHN) and minimum at bottom layer (88 VHN) for 20Mn Cr5 substrate.
In case of cladding on mild steel, the hardness on the clad layer is 168 VHN and at
bottom layer 66 VHN.
 The corrosion resistance and wear resistance of cladded specimen have

improved substantially with respect to substrate materials in both the cases - 20Mn
Cr5 steel and mild steel.
 The cross-sectional views of the clad layer have been studied under Scanning
Electron Microscope (SEM). It is observed that the clad layer does not have any
porosity or cracks. It indicates that there is a strong bonding at clad bead and
substrate interface, with exception in few samples.

FUTURE SCOPE OF WORK
 Experiments may be carried out in the range outside the experimental range
used in the present work.
 Possibility of heat transfer analysis of the clad bead zone through FEM
(Finite Element Method) and FDM (Finite Difference Method) may be
explored.
 The present experimental set-up can be modified by considering tooling
arrangement for curved surface cladding or overhead cladding.
 In the present work, the focus diameters of laser beam and stand-off distance
are considered constant. Experiments are to be conducted in the future with the
variation of these parameters to identify the effects of these factors on the clad
quality of the cladded surface.
 The existing experimental set up can be modified for cladding of large
surfaces with multi nozzle powder feeding system, so that cladding time is
shortened.
 The mathematical model can be refined further so that numerical results
given by the model would be more realistic.
 Experimenting with several other substrates and clad materials provides
enough scope of future work.

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A Ph.D.

School of Laser Science and Engineering

School of Laser Science & Engineering, Jadavpur University 2

Fig.2: A sectional view of laser

School of Laser Science & Engineering, Jadavpur University 3

School of Laser Science & Engineering, Jadavpur University 4

Identify test conditions

Identify control and noise factors

Define the data analysis procedure

Design the matrix experiment (OAs)

Conduct designed experiments

Analyze the data

Individual Relative Determination ANOVA and Performance

School of Laser Science & Engineering, Jadavpur University 6

Table 1: Control Factors & their Table 2: Experimental Layout using L9 OA

School of Laser Science & Engineering, Jadavpur University 7

X-Y WORK STATION ARGON GAS

Fig.4: THE SCHEMATIC ARRANGEMENT

Number (mm) (mm) (mm) Number (mm) (mm) (mm)

School of Laser Science & Engineering, Jadavpur University 9

Fig. 5: The photographic views of single clad

Fig.(b): 4 single clad beads

School of Laser Science & Engineering, Jadavpur University 10

Fig. (b): Double clad layer of Parallel tracks

Scan speed Laser

Clad Fig. 8: Combined effect of Powder Feed

School of Laser Science & Engineering, Jadavpur University 12

0.74 0.55 0.36 0.17

Powder Scan speed

Clad Fig.10: Combined effect of Scan Speed

1.15 1.4 0.15

School of Laser Science & Engineering, Jadavpur University 13

Fig.12: Combined effect of Powder Feed

School of Laser Science & Engineering, Jadavpur University 14

Fig. 14: Combined effect of Laser Power

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Fig16: Combined effect of Laser Power

0.29 0.41 0.51 0.61

Scan speed Laser

School of Laser Science & Engineering, Jadavpur University 16

0.21 0.310.41 0.51

Fig.18: Combined effect of Powder

School of Laser Science & Engineering, Jadavpur University 17

School of Laser Science & Engineering, Jadavpur University 18

School of Laser Science & Engineering, Jadavpur University 19

School of Laser Science & Engineering, Jadavpur University 20

Fig.20: Response diagram of S/N

Fig.21: Response diagram of S/N

School of Laser Science & Engineering, Jadavpur University 21

Fig.23: Response diagram of

Fig.24: Response diagram of S/N

School of Laser Science & Engineering, Jadavpur University 22

Table 4: Taguchi-optimized results and Validation (mild steel)

School of Laser Science & Engineering, Jadavpur University 24

Table 6: GA optimized results and Validation (mild steel)

School of Laser Science & Engineering, Jadavpur University 25

where, Xij represents the normalized value of jth response

School of Laser Science & Engineering, Jadavpur University 27

Where ; , = Reference data or best data

School of Laser Science & Engineering, Jadavpur University 28

Table 8: Grey relational coefficients and grades (mild steel)

School of Laser Science & Engineering, Jadavpur University 29

Clad Height (mm) 0.18333 0.21333