Numerical Investigation of the Effects of Process Parameters on Temperature Distribution and Cladding-Layer Height in Laser Cladding

To delve into the effects of process parameters on temperature distribution and cladding-layer height in laser cladding, as well as the interaction between these two aspects, a thermal–fluid coupling numerical model was established considering process parameters (i.e., laser power and scanning velocity), the Marangoni effect, molten pool dynamics, and solid–liquid transition. The numerical findings indicate that the Marangoni effect is the main factor for the growth of the cladding layer. The cladding-layer height increasingly influences heat-transfer efficiency as it develops. Higher laser power or lower scanning velocity, or a combination of both, can lead to higher cladding temperatures and greater cladding-layer height. Under the combination of laser power of 1750 W and scanning velocity of 4 mm/s, the numerical simulation predicts a cladding-layer height of 1.12 mm, which closely aligns with the experimentally determined height of 1.11 mm. Additionally, the comprehensive error being below 5% demonstrates the model’s considerable instructional value for practical applications.