Strategies for Increasing the Productivity of Pulsed Laser Cladding of Hot-Crack Susceptible Nickel-Base Superalloy Inconel 738 LC

• Main Authors: Christian Kästner, Matthias Neugebauer, Klaus Schricker, Jean Pierre Bergmann
• Format: Article
• Language: English
• Published: MDPI AG 2020-08-01
• Series: Journal of Manufacturing and Materials Processing
• Subjects: nickel-base superalloy; repair welding; hot-wire; pulse shaping; heat management; statistical analysis
• Online Access: https://www.mdpi.com/2504-4494/4/3/84

A novel repair strategy based on decoupled heat source for increasing the productivity of wire-assisted pulsed laser cladding of the γ’-precipitation strengthening nickel-base superalloys Inconel 738 low carbon (IN 738 LC, base material) and Haynes 282 (HS 282, filler material) is presented. The laser beam welding process is supported by the hot-wire technology. The additional energy is utilized to increase the deposition rate of the filler material by increasing feeding rates and well-defining the thermal management in the welding zone. The simultaneous application of laser pulse modulation allows the precise control of the temperature gradients to minimize the hot-crack formation. Accompanying investigations such as high-speed recordings and numerical simulations allow a generalized statement on the influence of the adapted heat management on the resulting weld seam geometry (dilution, aspect ratio and wetting angle) as well as the formation of hot-cracks and lack of fusion between base and filler material. Statistical analysis of the data—the input parameters like laser pulse energy, pulse shape, hot-wire power and wire-feeding rate in conjunction with the objectives like dilution, aspect ratio, wetting angle and hot-cracking behavior—revealed regression functions to predict certain weld seam properties and hence the required input parameters.