Calculation and verification of Start/Stop optimum overlapping rate on metal DLF technology

Laser cladding represents an advanced repair and modification technology for the failed parts and high-performance parts of controlled the surface onto the needing area. When the cylinder geometry or complex geometry which has circular and partition fusion is required, maybe there appears an overlap in poles of the laser clad track and linear or circular clad edge zone, and in Start/Stop zone of the laser clad track. When the distance of the overlap is not attached importance, the unsuitable height of the overlapping region may result in the defect of the coatings and even the failure of the parts. This paper establishes T-shape overlapping model and Start-Stop overlapping model, and reports several overlap strategies that are used to verify the model and tested to solve the overlapping problem. The 500W IPG fiber laser was used to perform laser cladding experiments, 45 steel substrate size: 100 × 100 × 10 mm and coating powder: YCF101 alloy powder. 3D measuring laser microscope was used to study the height of overlapping zone by different overlapping strategies. These strategies were designed according to different combinations of the poles and clad edge. Coating height inside the overlap zone was identified and overlapping formula was verified for YCF101alloy.