Process parameters investigation of a laser-generated single clad for minimum size using design of experiments

Purpose – This paper aims to investigate the effect of four important process parameters (i.e. laser focal distance, travel speed, feeding gas flow rate and standoff distance) on the size of single clad geometry created by coaxial nozzle-based powder deposition by high power laser. Design/methodology/approach – Design of experiments (DOE) and statistical analysis methods were both used to find optimum parameter combinations to get minimum sized clad, i.e. clad width and clad height. Factorial experiment arrays were used to design parameter combinations for creating experimental runs. Taguchi optimization methodology was used to find out optimum parameter levels to get minimum sized clad geometry. Response surface method was used to investigate the nonlinearity among parameters and variance analysis was used to assess the effectiveness level of each problem parameters. Findings – The overall results show that wisely selected four problem parameters have the most prominent effects on the final clad geometry...