Manufacture

Proc IMechE Part C:

J Mechanical Engineering Science
Comparing and analysing the 2023, Vol. 237(13) 2969–2989
Ó IMechE 2022
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characterisation of laser cladding of sagepub.com/journals-permissions
DOI: 10.1177/09544062221141267
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H13 tool steel

S Martin Vinoth and P Dinesh Babu

Abstract
Cladding-based repair has been found to be superior than welding or flame spraying repair approaches in terms of
extending die life. In this work, two different alloy powders, that is, CrNiW and CrNiFeAlZr were coated on H13 steel
using laser cladding. The laser power, powder feed rate and scanning speed were varied and the clad dimensions,
aspect ratio and dilution percentage were measured. The microhardness found in the CrNiW clad is 834 6 20 HV0.5,
which is higher than that of the CrNiFeAlZr clad (780 6 20 HV0.5) as well as the substrate clad (548 6 20 HV0.5).
CrNiW clad has a higher microhardness than CrNiFeAlZr clad and substrate, indicating that CrNiW laser cladding has
a significant impact on microhardness. The interface region for CrNiFeAlZr has 8.33% of C, which is less than the
interface region for CrNiW (10.65% of C) so that the microhardness at the interface in CrNiW clad is high. The XRD
patterns identified the common phase creation of Ni3C and Fe3C for CrNiFeAlZr and CrNiW coatings, while the
oxide formation was only seen in CrNiFeAlZr coatings and the addition of carbon content in the CrNiW clad layer
forms WC, Cr23C6, Ni3C and Fe3C. A response surface methodology with a Box-Behnken design is used in the
optimisation process.

Keywords
Laser cladding, microhardness, microstructure, CrNiW, CrNiFeAlZr, response surface methodology, optimisation, box-
Behnken design

Date received: 14 May 2022; accepted: 4 November 2022

Introduction parameters for clad profile generation are laser beam

power, scanning speed and clad powder feed rate.5 A
Coating methods are commonly used to improve the high hardness in the clad region was achieved due to
mechanical properties, corrosion resistance and wear grain refinement and flocculated NiTi particles.6
resistance as well as to repair damaged components. Using an Nd:YAG laser source, CrMoTaWZr com-
H13 tool steel, which has good hot working proper- plex concentrated alloy (CCA) was deposited on the
ties, is generally used for producing dies and moulds.1 H13 steel substrate. The life duration of the die was
Tool steels such as H11 and H13 are widely used in extended by covering it with CrMoTaWZr CCAs,
hot working conditions such as forging, die casting which contains zirconium and has a strong resistance
and extrusion.2 H13 tool steel has dimensional stabi- to corrosion by alkalis, acids and salt water.7 Simsek
lity, great hot working properties and high surface et al.8 coated TiC nanoparticles on H13 die steel by a
toughness properties even at a temperature range of CO2 laser in a N2 environment, resulting in a crack-
200–800°C. Due to repeated thermal cycles, the life free and homogeneous coating with three times the
of the dies reduces gradually and fails over a period hardness of the substrate. Jinkang et al.9 investigated
of time. Laser cladding is used to repair damaged dies
by adding the material over the damaged dies.3
Kattire et al.4 performed the coating of crucible pow- School of Mechanical Engineering, SASTRA Deemed to be University,
der metallurgy (CPM 9V) powder on the H13 die Thanjavur, Tamilnadu, India
steel substrate using CO2 laser. A clad hardness of
Corresponding author:
800 HV was achieved due to hard vanadium carbide, P Dinesh Babu, School of Mechanical Engineering, SASTRA Deemed to
which is four times higher than the substrate metal be University, Thanjavur, Tamilnadu 613 401, India.
hardness. The most accountable laser cladding Email: [email protected]
2970 Proc IMechE Part C: J Mechanical Engineering Science 237(13)

laser cladding on H13 steel with Ni-based alloy using tooling applications. It was found that the coating
pulsed YAG laser equipment in which the Ni-based has excellent wear resistance at high temperature. The
alloy was mixed with TiC and CeO2 to rise the wear hard phases M7C3 and M23C6 were found in the coat-
resistance of the H13 steel base. Chen and Xue10 ing, subsidising to the initial microhardness of the
deposited CPM 3V, 9V and 15V on hardened coating. In addition, increased WC content in the
wrought H13 steel plates with Nd:YAG laser source. coating resulted in the formation of FeWC-like com-
The wear resistance was improved due to phase trans- pounds and a significant increase in the microhard-
formation. Wall et al.11 coated a high-entropy alloy ness.23 Yao and Fang24 investigated the numerical
(HEA) CoNiFeCrAlTi on H13 steel die head to eval- simulations of nickel-base alloy powder coating on
uate the effectiveness of the clad region and also var- H13 steel by laser cladding method. It was found that
ied the laser fluence to determine the optimum the thermal stress at the sample site is directly propor-
condition. Xue et al.12 deposited Ni25 alloy (transi- tional to the laser power and scanning speed, and the
tional layer) on H13 tool steel by laser cladding and thermal stress increases as the laser power and scan-
later deposited Fe104 (strengthening layer) alloy over ning speed increase. Wang et al.25 prepared Stellite-6/
the coating surface. The existence of nickel improves WC metal matrix composite deposited on H13 die
corrosion resistance, increased toughness, resistance steel using laser cladding technique with cobalt-
to impact and strengthened metal alloys. Farahmand coated tungsten carbide (WC-12Co) particles and
and Kovacevic13 coated AISI H13 feedstock material Stellite-6 powder. The literature survey shows that
over steel base by diode laser. The impact of input many experiments have been conducted on laser clad-
process parameters such as laser power, powder flow ding of AISI H13 steel substrate using CPM 9V,4
rate, scanning speed and clad microhardness of the NiTi,6 CrMoTaWZr,7 TiC nanoparticles,8 Ni-based
clad profile were studied. The consequences of input alloy powders,9 CoFeNiCrAlTi HEA,11 stellite 6-
process parameters such as laser beam power, the Cr3C2-WS2 self-lubricating composite,19 Ti3AlC2-
feed rate of clad powder, stand-off distance and flow reinforced Co-based alloy,20 NiCrAl-WC,21 Fe-based
rate of carrier gas on the responses such as powder coatings with varied WC,23 Stellite-6/WC metal
catchment efficiency, clad height and clad width were matrix composite,25 CrNi coatings with different
examined, and a simple regression model was estab- TiO2,26 CoCrFeNiBSi HEA,27 NiCrBSi + Ni/MoS2
lished using the RSM model.14–16 Jeyaprakash and powder,28 CoCrFeNiTiNbB1.25 HEA,29 FeCoCrNi
Yang17 studied the wear properties of two different MnAl HEA,30 WC/Co-Cr alloy,31 WC/Ni,32 Nickel-
alloy powders NiCrFeMoNb and FeCrMoVC coated based composite,33 Al2CoCrCuFeNi,34 FeCoCrNiMn
on a nickel-based superalloy and concluded that the Alx,35 Cr–Ni–Al2O3–TiO2 composite,36 FeMnCrNi
laser-cladded region showed higher wear resistance Co + x(TiC) composite HEA,37 and NiCrAl-SiC.38
with improved hardness. CrNi is generally used for However, CrNiW and CrNiFeAlZr clad powders
increasing thermal fatigue resistance and corrosion were not considered so far in laser cladding of H13
resistance. The WC/Ni powder was mixed with H13 steel. CrNi-based alloy powders are a new type of
tool steel substrate, and they concluded that the laser- alloy with outstanding features such as wear resis-
cladded surface showed higher wear resistance with tance, oxidation resistance and corrosion resistance.
better hardness.18 Chen et al.19 applied the coating A few researches have been published on enhancing
over H13 die steel by laser cladding system with com- tool life by coating H13 steel with CrNi-based alloy
posite coatings of stellite 6-Cr3C2-WS2 using a powders. Moreover, previous studies on laser clad-
LDM3000-60 semiconductor laser and concluded ding parameter optimisation on H13 tool steel are
that the hardness of the cladded surface is roughly 2.5 limited. However, no study on optimising and com-
times greater than the H13 steel substrate because of paring CrNiW and CrNiFeAlZr depositions on H13
the formation of g-(Fe,Co)/Cr7C3, (Cr,W)C and den- tool steel using the laser cladding procedure has been
dritic crystals in the covering region. The addition of found. Therefore, this work focuses on comparing
Ti3AlC2 hard phase to a Co-based coating can and analysing the differences between the selected
improve its hardness, and the strong activity of Al in clad powders in terms of properties. Finally, micro-
Ti3AlC2 easily creates an Al2O3 film, which consider- hardness distribution along with the depth of laser-
ably increases coating oxidation resistance at high cladded samples has been evaluated. There were no
temperatures.20 Wei and Dejun21 prepared NiCrAl- huge cracks on the cladded surface as well as the
WC coatings with varied WC contents on H13 die cross-section of the coatings. Hence, the interaction
tool steel by laser cladding method. It was found that effects of input process variables are evaluated, and
the hardness of NiCrAl-WC coating improves as the optimum process variables are reported in this work.
WC percentage rises, and adding WC to NiCrAl-WC Damaged H13 tool steel extrusion dies can be
coatings can improve their wear resistance. Chen and repaired using laser cladding with CrNiW clad pow-
Xue22 fabricated the wear-resistant high-performance der, and this repair method provides significant
CPM 9V die steel coating on hardened AISI H13 tool improvement in die life as well as mechanical and
steel by laser cladding for prospective automotive metallurgical properties. In addition, the impact of
Martin Vinoth and Dinesh Babu 2971

Table 1. Chemical composition of H13 substrate.

Elements C Mn Si Cr Mo V Cu P S Fe

wt.% 0.45 0.42 0.95 4.88 1.19 1.00 0.02 0.01 0.03 Balance

Table 2. Chemical composition of clad powder materials.

CrNiW (wt.%) Cr – 75 Ni – 24 W – 1.00 – –

CrNiFeAlZr (wt.%) Cr – 22 Ni – 17.5 Fe – 55 Al – 5 Zr – 0.5

input variables on clad parameters such as clad To remove impurities before cladding, these plates
height, clad depth and clad width has been were cleaned with acetone and preheated at 300°C to
investigated. minimise the defects. The line diagram of the experi-
mental operation, laser cladding set-up and specimens
after laser cladding are shown in Figure 2(a) to (c),
respectively.
Experimental procedures
Substrate material and cladding powder Process parameters
H13 steel plate of 5 mm thickness was utilised as clad
The laser power, scanning speed and feed rate of clad
substrate, purchased from Pandi Steel and Alloys Pvt.
powder were taken as the laser cladding input process
Ltd., Madurai. The average microhardness value of
parameters. The input process parameter range was
the substrate is 548 6 20 HV0.5. The chemical compo-
chosen from initial trial experiments. A constant laser
sition of H13 tool steel substrate is given in Table 1.
beam with a 3 mm diameter and focal length of
CrNiW and CrNiFeAlZr powders, purchased
18 mm was used during the experiment. The cladding
from, Royal scientific and Eswar scientific Pvt Ltd.,
input factors and their levels are shown in Table 3.
Trichy, were used as clad materials. The selected ele-
mental powders with higher purity were well mixed
with a non-equiatomic ratio. The chemical composi- Hardness and microstructure
tions of clad powders are given in Table 2. The aver- Wire-cut electrical discharge machining was used to
age particle size of nickel and chromium was around make cross-section of the deposited specimens for
149 mm, and the particle size of zirconium, tungsten, metallurgical and mechanical examination. The cross
iron, and aluminium was around 125, 44, 74 and section of the cut specimens was prepared by the
88 mm, respectively. The powders employed in this metallographic procedure of mounting, polished by
investigation had particle sizes ranging from 44 to SiC papers (80, 240, 400, 800, 1200 grit) and followed
149 mm. The mixing of powders was done in a plane- by cloth polishing with alumina powders to attain a
tary ball mill with a maximum speed of 230 rpm and mirror-like appearance. The polished specimens were
a time duration of 2 h with a ZrO2 ball having a dia- etched with the standard solution involving of 10%
meter of 6 mm.21 of nitric acid and 90% of ethanol to reveal the micro-
After ball milling, the average particle size of structure.4 The scanning electron microscope JEOL
CrNiW alloy is 85.99 mm and that of CrNiFeAlZr is 6360 and energy-dispersive X-ray spectroscopy (EDS)
78.76 mm, and the Scanning Electron Microscopy were used to analyse and predict the distribution of
(SEM) micrograph of ball-milled clad powders with the elements in the obtained structure. An optical
particle size and chemical composition is shown in microscope was used to analyse the microstructure of
Figure 1(a) to (d). the different regions after cladding. The cross-section
microhardness difference from the clad region to the
base was measured using a Shimadzu Vickers micro-
hardness tester. A load of 4.9 N was applied for the
Laser cladding: Experimental set-up
hardness test with a loading duration of 15 s. The
The laser cladding trials were performed at Magod grain size was measured using the linear intercept
Laser Machining Private Limited, Bengaluru. The method.
cladding was carried out by 4 kW, CO2 laser and
coaxial nozzle for powder feeding, with Ar as the car-
rier gas. Ar gas was blown coaxially onto the sample X-ray diffraction analysis
surfaces for shielding to minimise oxidation with the The phase structures of the H13 tool steel substrate
flow rate of 25 l/min. as-received powders and coatings were identified by
2972 Proc IMechE Part C: J Mechanical Engineering Science 237(13)

Figure 1. SEM image of ball milled powders: (a) CrNiW, (b) CrNiFeAlZr, (c) EDX analysis of CrNiW powder and (d) EDX analysis
of CrNiFeAlZr powder.

XRD using CuKa radiation of wavelength 1.5406 Å design and statistical modelling. RSM provides the
(D8 Focus, Bruker, Germany) operating at 45 kV and explicit relationship between the process parameter
30 mA. The samples were scanned at a speed of and the target responses with the minimum number
3°/min and the scanning range from 20° to 80° (2u). of experiments.13,15,39 The RSM Box-Behnken design
The obtained X-ray diffraction patterns were matched (BBD) of 14 trials was conducted for both the clad
with the standard database. powders. The developed regression model is verified
by the ANOVA technique. Later, the validation tests
were implemented on the samples with the optimum
Response surface methodology (RSM) parameters. The Box-Behnken design combined with
The analysis of variance (ANOVA) method was used the regression model provided a modest, effective and
for assessing the importance of the model. ANOVA efficient method for investigating the influence of pro-
is used to examine whether the cladding input process cess factors on preferred outputs and multi-objective
variables and the collaboration of these input vari- optimisation. During the laser cladding process,
ables have an important impact on the clad profile multi-objective optimisation is used to determine the
and to recognise whether the best model is significant best parametric configuration for achieving the target
or not. RSM is an optimisation tool for experimental clad bead dimension.
Martin Vinoth and Dinesh Babu 2973

Figure 2. (a) Schematic of the laser cladding process, (b) photograph of the laser cladding process set-up and (c) samples after laser
cladding.

Table 3. Process parameters and its levels. determined using SEM. The cross-sectional images of
clad tracks exhibited three different zones, namely the
Sl. No. Parameters Level 1 Level 2 Level 3 clad region, HAZ and substrate.6 The BBD available
1 Laser power (kW) 1.7 2.1 2.5
in the design-expert software was used to decide the
2 Scanning speed 500 650 800 optimum number of experimental combinations for
(mm/min) laser cladding. The rows indicate the test numbers
3 Powder feed rate 8 10 12 and the column expresses the three levels of input pro-
(g/min) cess parameters. The trials were accompanied using
the same set of parameters, and the responses are
shown in Tables 4 and 5 for the two different powders
CrNiFeAlZr and CrNiW, respectively.

Metallographic structure
After laser cladding, CrNiW and CrNiFeAlZr pow-
ders are dispersed uniformly along the surface, which
is evident from the average thickness of CrNiW
(924.42 mm) and CrNiFeAlZr (952.34 mm) powders
as shown in Figure 4(a) and (b).
The microstructure of the clad region and substrate
is shown in Figure 5(a) and (b). The substrate consists
of lath martensite, fine pearlite and M23C6 and M7C3
carbides.40 The carbides are dispersed uniformly in
the ferrite matrix. The martensite has the form of a
lath if it contains 0.6% of carbon for tool steel, and if
it contains more than 1% of carbon, it will have a
plate-like structure. Between those two percentages,
the physical form of the grains is a mixture of the lath
and plate martensite.41 The grain sizes of CrNiW and
Figure 3. Cross-sectional view of a clad bead notation. CrNiFeAlZr powders are measured by the linear
intercept technique. The average grain sizes of CrNiW
Results and discussion and CrNiFeAlZr after cladding are 4 and 17 mm,
respectively. The interface thickness between CrNiW
Clad profile clad and substrate is around 2 mm and that between
In total, 14 trials were conducted based on the design CrNiFeAlZr clad and substrate is around 7 mm. The
of experiments (DoEs) for two different powders, diffusion of atoms is much higher in CrNiFeAlZr
namely CrNiW and CrNiFeAlZr. Figure 3 shows the than CrNiW, so the interface thickness is higher in
cross-sectional view of a clad bead and describes the CrNiFeAlZr than CrNiW. Diffusion occurs in both
geometrical features used: clad width (W), clad depth the clad powders by providing a good metallurgical
(D) and clad height (H).22 The clad geometry was bonding.
2974 Proc IMechE Part C: J Mechanical Engineering Science 237(13)

Table 4. Design matrix with response variables for CrNiFeAlZr.

Sample Laser beam Scanning speed Powder feed Height Width Depth Aspect Dilution
power (kW) (mm/min) rate (g/min) (mm) (mm) (mm) ratio (%)
H W D W/H D/(D + H)

1 2.1 500 8 0.5331 2.5561 0.5261 4.7947 0.4966

2 2.1 650 10 0.7552 2.4586 0.4869 3.2555 0.3919
3 2.5 500 10 0.8956 2.6954 0.5969 3.0096 0.3999
4 1.7 650 12 0.8235 2.6234 0.3141 3.1856 0.2761
5 2.1 800 8 0.5516 2.2231 0.3816 4.0302 0.4089
6 1.7 500 10 0.8522 2.5963 0.3968 3.0465 0.3176
7 2.1 650 10 0.7363 2.4886 0.4969 3.3798 0.4029
8 2.1 500 12 0.9492 2.6045 0.4292 2.7438 0.3113
9 2.1 800 12 0.7792 2.3498 0.3442 3.0156 0.3063
10 2.5 650 12 0.8657 2.7242 0.4022 3.1468 0.3172
11 1.7 800 10 0.8257 2.3571 0.2562 2.8546 0.2368
12 2.5 800 10 0.8669 2.4032 0.3691 2.7721 0.2986
13 1.7 650 8 0.5011 2.5021 0.3451 4.9932 0.4078
14 2.5 650 8 0.5418 2.6031 0.4561 4.8045 0.4571

Table 5. Design matrix with response variables for CrNiW.

Sample Laser beam Scanning speed Powder feed Height Width Depth Aspect Dilution
power (kW) (mm/min) rate (g/min) (mm) (mm) (mm) ratio (%)
H W D W/H D/(D + H)

1 2.1 500 8 0.5016 2.4021 1.4239 4.7888 0.7394

2 2.1 650 10 0.7593 2.3523 1.3066 3.0979 0.6324
3 2.5 500 10 0.8991 2.5022 1.8368 2.7831 0.6713
4 1.7 650 12 0.8656 2.5055 0.4371 2.8945 0.3355
5 2.1 800 8 0.4856 2.2568 1.2035 4.6474 0.7125
6 1.7 500 10 0.8643 2.4572 0.5856 2.8429 0.4038
7 2.1 650 10 0.7493 2.3623 1.2866 3.1526 0.6319
8 2.1 500 12 0.9286 2.5045 1.3822 2.6971 0.5981
9 2.1 800 12 0.7955 2.4652 1.1121 3.0989 0.5829
10 2.5 650 12 0.8942 2.5652 1.6922 2.8687 0.6542
11 1.7 800 10 0.8195 2.3921 0.4195 2.9189 0.3385
12 2.5 800 10 0.8448 2.4031 1.5856 2.8445 0.6524
13 1.7 650 8 0.5022 2.2312 0.4837 4.4428 0.4906
14 2.5 650 8 0.5315 2.4656 1.7256 4.6389 0.7645

Figure 4. SEM image of laser clad specimens with thickness measurements: (a) CrNiW clad (2.1 kW, 650 mm/min and 10 g/min) and
(b) CrNiFeAlZr clad (2.1 kW, 650 mm/min and 10 g/min).
Martin Vinoth and Dinesh Babu 2975

columnar crystal distribution prolonged from the bot-

tommost to the central of the coating, and the dendri-
tic structure in the middle of the coating gradually
grown into an equiaxed structure.42,43 When the laser
beam leaves the molten pool, the temperature drops
quickly and the molten pool undergoes multiple com-
plicated modifications. The microstructure evolution
in the coating is determined by transformations,
which primarily comprise the solidification process
and solid state phase change. As a result, studying the
Figure 5. Optical micrographs of laser clad specimens: (a) solidification process and the temperature-dependent
CrNiFeAlZr clad (2.1 kW, 650 mm/min and 10 g/min) and (b) phase fraction is required and fascinating.28
CrNiW clad (2.1 kW, 650 mm/min and 10 g/min).

SEM-EDS analysis
The microstructures obtained through SEM are The EDS analysis can be used to map out the lateral
shown in Figure 6(a) to (c). Figure 6(a) clearly shows distribution of elements from the scanned area or to
the lath martensite structure of H13 steel substrate.31 identify the elemental composition of specific spots.
Figure 6(b) shows elongated coarse grains in the laser- To determine the elemental composition of the sub-
clad region (CrNiFeAlZr); in contrast, fine grains are strate, clad and interface regions, SEM-EDS analysis
noted in CrNiW clad region as shown in Figure 6(c). (point analysis) was conducted in the selected regions,
A higher temperature experienced by CrNiFeAlZr in and the results are shown in Figures 7 to 11.
laser processing leads to recrystallisation and grain Figure 7(a) to (c) shows the SEM-EDS results of
growth (coarse grain) formed in the clad region. the H13 substrate. As shown, the percentage of iron
Owing to the high melting point of CrNiW, no recrys- and chromium is higher in the substrate. Figure 8(a)
tallisation occurs and fine grains are formed on the to (c) shows the spectrum spotted on the laser-cladded
clad region. Due to the quick heat dissipation of the region of CrNiFeAlZr, which contains 19.06%,
base region, the ratio (G/R) of temperature gradient 16.68%, 52.54%, 5.57% and 0.42% of Cr, Ni, Fe, Al
(G) to solidification growth rate (R) on the interface and Zr, respectively. Figure 9(a) to (c) displays the
region was the highest at the start of solidification. elemental data of the interface zone of CrNiFeAlZr,
Furthermore, because the G/R rate near the base which confirms 8.63% of Cr, 8.33% of C and 4.31%
region was high and the columnar crystal growth of Ni. In the interface, Al is less (1.47 wt.%).
orientation was against the thermal diffusion path, a Figure 10(a) to (c) depicts the elemental analysis of
distinctive feature of columnar crystals growth per- laser clad region of CrNiW, which has 66.97% and
pendicular to the melting pool interface occurred.21 22.05% of Cr and Ni, respectively, with less amount
Each higher-to-lower region of the coating showed an (0.85%) of W. The interface of CrNiFeAlZr region
equiaxed to columnar crystal conversion. The size of contains 8.33% of C, which is less than that of the
columnar, dendritic and equiaxed structures grew in interface region of CrNiW (10.65% of C); due to this,
proportion to the increase in specific energy; the the microhardness is also high at the interface of

Figure 6. SEM micrographs laser clad specimens: (a) base metal, (b) CrNiFeAlZr clad (2.1 kW, 650 mm/min and 10 g/min) and (c)
CrNiW clad (2.1 kW, 650 mm/min and 10 g/min).
2976 Proc IMechE Part C: J Mechanical Engineering Science 237(13)

Figure 7. (a) SEM image, (b) EDS spectrum and (c) EDS chemical characterisation of substrate.

Figure 8. (a) SEM image, (b) EDS spectrum and (c) EDS chemical characterisation of CrNiFeAlZr clad (2.1 kW, 650 mm/min and
10 g/min).

Figure 9. (a) SEM image, (b) EDS spectrum and (c) EDS chemical characterisation of CrNiFeAlZr Interface (2.1 kW, 650 mm/min
and 10 g/min).

CrNiW clad (Figure 11). The chosen elemental pow- Microhardness

ders are responsible for the carbide formation during Figure 14(a) and (b) shows the hardness distribution
the laser cladding process, hence the clad surface and along with the depth from the laser clad surface of
the interface region for CrNiFeAlZr and CrNiW CrNiW and CrNiFeAlZr, respectively. Figure 14(a)
coatings have a little greater carbon content. shows the hardness variation of laser clad specimens
Figure 12(a) to (e) illustrates the EDS maps of the of CrNiW at different process parameters. Almost
major alloying elements Cr, Ni, Al, Fe and Zr, respec- uniform high hardness values (825–843 HV0.5)
tively. Figure 13(a) to (c) shows the major alloying was observed in the clad region (Figure 14(a)) for dif-
elements Cr, Ni and W, respectively. ferent parameters. Similarly, uniform hardness values
Martin Vinoth and Dinesh Babu 2977

Figure 10. (a) SEM image, (b) EDS spectrum and (c) EDS chemical characterisation of CrNiW clad (2.1 kW, 650 mm/min and 10 g/min).

Figure 11. (a) SEM image, (b) EDS spectrum and (c) EDS chemical characterisation of CrNiW interface (2.1 kW, 650 mm/min and
10 g/min).

Figure 12. EDS maps of the clad region for CrNiFeAlZr (2.1 kW, 650 mm/min and 10 g/min): (a) chromium element, (b) nickel
element, (c) aluminium element, (d) iron element and (e) zirconium element.
2978 Proc IMechE Part C: J Mechanical Engineering Science 237(13)

Figure 13. EDS maps of the clad region for CrNiW (2.1 kW, 650 mm/min and 10 g/min): (a) chromium element, (b) nickel element
and (c) tungsten element.

Figure 14. Microhardness plotted versus distance from surface in laser cladded samples: (a) CrNiW and (b) CrNiFeAlZr.

(769–791 HV0.5) were recorded in the clad region of different regions of the clad specimens. For CrNiW
CrNiFeAlZr, as shown in Figure 14(b). The hardness powders, a maximum hardness of 843 HV0.5 was
enhancement in the clad region is due to the large achieved for a laser beam power of 2.5 kW, scanning
thermal gradient formed resulting in carbides and fine speed of 650 mm/min and powder feed rate of 12 g/
supersaturated martensite in the microstructure. min. For CrNiFeAlZr powders, a maximum hardness
Later, at 0.5 mm depth, the hardness is slightly of 791 HV0.5 was achieved for a laser power of
reduced to 803–819 and 759–769 HV0.5 for CrNiW 2.5 kW, scanning speed of 650 mm/min and powder
and CrNiFeAlZr clads, respectively. The small reduc- feed rate of 12 g/min.
tion in hardness at depth is due to the lower cooling
rate compared to the top surface clad region.
An unusual increase in hardness is observed in the
XRD analysis
interface region with the average hardness of 856 6 20 The XRD patterns for the substrate, powders and
and 786 6 20 HV0.5 for CrNiW and CrNiFeAlZr, cladding layers are shown in Figure 15(a) to (c). The
respectively, which is due to the creation of martensite ferrite peaks observed for the as-received H13 tool
along with carbides in the interface zone. Following steel substrate were determined by X-ray diffraction,
this, a moderate reduction of hardness is recorded and they occur at 2u angles of 45.068° and 65.186°
along with depth into the HAZ and reaches the base matching the (110) and (200) planes, respectively, as
metal hardness of 2.5 mm depth. The Vickers microin- shown in Figure 15(a).31 The XRD patterns for the
dentation variation shown in Figure 14(a) and (b) first mixture of CrNiW and CrNiFeAlZr powders are
confirms the hardness differences observed in the presented in Figure 15(b) and (c), respectively. The
Martin Vinoth and Dinesh Babu 2979

Figure 15. XRD pattern for: (a) H13 tool steel as-received, (b) CrNiW and (c) CrNiFeAlZr.

patterns were recognised with the standard informa- addition of carbon content in the CrNiW coating
tion file. The phases in the CrNiW and CrNiFeAlZr forms WC, Cr23C6, Ni3C and Fe3C. The elements Cr,
cladding layers were identified by XRD, and the com- Fe and Al reacted with O to form Al2O3, Cr2O5,
plex intermetallic compounds are combined into sim- Fe2O3, Fe3O4 and Cr3O8 oxides in CrNiFeAlZr clad-
ple phases as shown in Figure 15(b) and (c). The ding. The common formation of Ni3C and Fe3C for
phases present in the cladding layer of CrNiW are CrNiFeAlZr and CrNiW coatings were identified
Ni2W4C, WC, Cr23C6, (Fe, Ni), Ni3C, CrNiFe and from XRD patterns. During the solidification pro-
Fe3C as shown in Figure 15(b). When Ni and W cess, the atomic radius of carbon atoms is tiny, allow-
atoms are inserted into W3C during the process, a ing for easy diffusion. As a result, carbides can be
new Ni2W4C phase is formed. The major phases pres- easily formed, increasing the hardness of the coating.9
ent in the cladding layer of CrNiFeAlZr are Cr2O5, The primary elements of the initial powders are Cr,
Al2O3, Fe3C, Ni3C, NiZr2, Fe3O4, FeZr2, Fe2O3 and W and Ni as expected. The clad layers contain a vari-
Cr3O8 as shown in Figure 15(c). Diffraction peaks of ety of WC, NiCrFe and NiFe phases. The presence of
Cr3O8 for CrNiFeAlZr cladding and Fe3C for CrNiW NiFe and NiCrFe alloy phases in the clad layer
cladding can be visibly seen. In CrNiFeAlZr clad, matrix indicates dilution caused by melting and con-
Cr23C6 is not present due to its full disintegration dur- tact between the clad and base metal. Fe and Cr dif-
ing laser cladding. Clad layer compounds such as fusion from the base metal enhances the binder
Al2O3 and WC have excellent wear and corrosion phase, resulting in an alloy. Furthermore, high-
resistance. The outcomes of the analyses of XRD pro- temperature revelation causes some inter-diffusion
pose that CrNiFeAlZr cladding primarily consists of with the carbides, probably of nickel or iron, causing
oxide phases. the lattice to enlarge.18 As a result, the material sur-
No oxygen element was found in the CrNiW clad face, which is effectively protected by the (Cr, W) C
layer, so that there is no oxide formation and carbides, is difficult to wear.19 The g-(Ni, Fe) dense
2980 Proc IMechE Part C: J Mechanical Engineering Science 237(13)

Table 6. Analysis of variance analysis for the clad height of CrNiFeAlZr clad powder.

Source of Sum of Degrees of Mean F-value p-Value Source

variation squares freedom squares

Model 0.3009 9 0.0334 99.8762 0.0002 Significant

A-Laser power 0.0035 1 0.0035 10.4763 0.0318
B-Speed 0.0053 1 0.0053 15.9537 0.0162
C-Feed rate 0.208 1 0.208 621.3861 \ 0.0001
AB 1.21 3 10206 1 1.21 3 10206 0.0036 0.9549
AC 5.62 3 10207 1 5.62 3 10207 0.0016 0.9693
BC 0.0088 1 0.0088 26.5359 0.0067
A2 0.007 1 0.007 21.1612 0.01
B2 0.0144 1 0.0144 43.2964 0.0028
C2 0.0385 1 0.0385 115.1937 0.0004
Residual 0.0013 4 0.0003
Lack of fit 0.0011 3 0.0003 2.1657 0.4545 Not significant
Error 0.0001 1 0.0001
Corrected total 0.3022 13

R2: 0.9955; Adj R2: 0.9856; Pred R2: 0.9362; Adeq precision: 28.2137.

solution generated by iron and nickel was partially high-temperature wear pursuance of the FeMnCr
converted into iron and nickel compounds due to the NiCoAlx cladding layers while also improving the
quick heating and cooling speed of the laser cladding enactment of H13 tool steel substrate. On the surfaces
method, containing Ni3Fe and FeNi phases, afford- of FeMnCrNiCoAlx cladding layers, fine and dense
ing to the binary phase diagram of iron and nickel. a-Al2O3 was produced differently. a-Fe2O3 and
The disintegration temperature of WC was 1050– Cr2O3 enhanced heterogeneous nucleation of a-
2100°C, and during the laser cladding technique, the Al2O3, which increased the high-temperature oxida-
WC phase was partially dissolved into W2C and C tion resistance of the cladding layer.35 Al2O3 layer
phases, increasing the coating hardness to an extent.21 considerably enhanced the coating oxidation resis-
The hard phases M7C3 and M23C6 were found in the tance at high temperatures.20,44 At high temperatures,
coatings, subsidising to the primary microhardness of the C in the powder formed the carbides Ni3C and
iron-based coatings.23 This combination of Cr23C6 Fe2C, which possessed a high hardness.45 Fe23C6 and
and Cr7C3 provided superior thermal stability and g-Ni are the principal phase constituents of Ni25
high-temperature oxidation resistance.31 According coatings, whereas Ni25 + (ZrO2 + C) composite
to prior research, the compounds could be (Fe, coatings comprise not only g-Ni and (Fe, Ni)23C6,
Cr)7C3 and Cr23C6 because the alloy contains Cr, but also ZrC, NiZr2, Ni7Zr2 and Fe3C.46 The pres-
which causes the formation of (Fe, Cr)7C3 carbide ence of a considerable amount of Cr7C3 and Cr23C6
rather than Fe3C as Cr has a stronger inclination to carbides could result in a rather robust wear resistant
form carbides with iron. The diffraction patterns of structure that is resistant to sliding.47
CrNiW clad layer include not only WC but also
Ni2W4C and CrNiFe, implying the creation of an
intermetallic compound in the matrix of the CrNiW
Response surface methodology (RSM)
clad surface. The peaks related to Ni binder were Development of the mathematical model. ANOVA analy-
determined in accordance with a CrNiFe alloy, indi- ses for the responses are shown in Tables 6 to 11.
cating that chromium and iron from the base metal Second-order regression is used to analyse all of the
were disintegrated in the nickel binder phase, thereby output responses. The main constraint to fitting the
showing a dilution effect. The WC particles present model, ‘lack of fit’, is not important in the ANOVA
enhance the bulk hardness of the clad WC/Ni, result- analysis. The sufficiency measurements, such as
ing in a better wear resistance. Furthermore, the vol- adjusted R2, are closer to 1, as required, demonstrating
ume fraction of tungsten carbide in the clad layers the model’s fitness. For clad height of CrNiFeAlZr
was shown to be connected to abrasive wear resis- powder (shown in Table 6), laser power (A); scanning
tance, with larger volume fractions resulting in a speed (B); feed rate (C) and interactions BC, A2, B2
somewhat greater wear resistance.32 The oxide was and C2 are essential model terms. The ‘Pred R2’ of
unable to protect the base metal in the high- 0.9362 is in reasonable agreement with the ‘Adj R2’ of
temperature air medium, and the high-temperature 0.9856. The model’s F-value of 99.88 indicates that it
oxidation enactment of the matrix worsened. On is significant. A ‘lack of fit F-value’ of 2.17 implies that
the surface of the H13 substrate, (Cr,Fe)2O3 oxide there is no meaningful relationship between the pure
developed, reducing its high-temperature oxidation error. Due to noise, there is a 45.45% chance that a
resistance. The aluminium element increased the significant ‘lack of fit p-value’ will occur. The
Martin Vinoth and Dinesh Babu 2981

Table 7. Analysis of variance analysis for the clad width of CrNiFeAlZr clad powder.

Source of Sum of Degrees of Mean F-value p-Value Source

variation squares freedom squares

Model 0.2642 9 0.0293 64.7848 0.0006 Significant

A-Laser power 0.015 1 0.015 33.2104 0.0045
B-Speed 0.1565 1 0.1565 345.425 \ 0.0001
C-Feed rate 0.0217 1 0.0217 48.076 0.0023
AB 0.0007 1 0.0007 1.5495 0.2812
AC 1 3 10208 1 1 3 10208 2.2 3 10205 0.9965
BC 0.0015 1 0.0015 3.3819 0.1398
A2 0.0384 1 0.0384 84.8351 0.0008
B2 0.0157 1 0.0158 34.8084 0.0041
C2 0.0028 1 0.0028 6.3494 0.0654
Residual 0.0018 4 0.0004
Lack of fit 0.0013 3 0.0004 1.0094 0.607 Not significant
Error 0.0004 1 0.0004
Corrected total 0.266 13

R2: 0.9931; Adj R2: 0.9778; Pred R2: 0.9112; Adeq precision: 27.1111.

Table 8. Analysis of variance analysis for the clad depth of CrNiFeAlZr powder.

Source of Sum of Degrees of Mean F-value p-Value Source

variation squares freedom squares

Model 0.1038 9 0.0115 10.5146 0.0185 Significant

A-Laser power 0.0327 1 0.0327 29.8798 0.0054
B-Speed 0.0446 1 0.0446 40.731 0.0031
C-Feed rate 0.006 1 0.006 5.4745 0.0794
AB 0.0019 1 0.0019 1.7327 0.2584
AC 0.0001 1 0.0001 0.1195 0.747
BC 0.0008 1 0.0008 0.8067 0.4199
A2 0.0131 1 0.0131 11.9566 0.0259
B2 0.0017 1 0.0017 1.5598 0.2798
C2 0.0075 1 0.0075 6.861 0.0588
Residual 0.0043 4 0.001
Lack of fit 0.0043 3 0.0014 28.9223 0.1356 Not significant
Error 0.00005 1 0.00005
Corrected total 0.1082 13

R2: 0.9594; Adj R2: 0.8681; Pred R2: 0.3566; Adeq precision: 9.9130.

Table 9. Analysis of variance analysis for the clad height of CrNiW clad powder.

Source of Sum of Degrees of Mean F-value p-Value Source

variation squares freedom squares

Model 0.3574 9 0.0397 420.6401 \ 0.0001 Significant

A-Laser power 0.0017 1 0.0017 18.4333 0.0127
B-Speed 0.0077 1 0.0077 81.5537 0.0008
C-Feed rate 0.2675 1 0.2675 2833.537 \ 0.0001
AB 2.25 3 10205 1 2.25 3 10205 0.2389 0.6506
AC 1.22 3 10207 1 1.22 3 10207 0.0012 0.973
BC 0.0034 1 0.0034 36.3064 0.0038
A2 0.0121 1 0.0121 128.548 0.0003
B2 0.0053 1 0.0053 57.0744 0.0016
C2 0.0441 1 0.0441 468.0027 \ 0.0001
Residual 0.0003 4 9.44 3 10205
Lack of fit 0.0003 3 0.0001 2.1845 0.4528 Not significant
Error 0.00005 1 0.00005
Corrected total 0.3578 13

R2: 0.9989; Adj R2: 0.9965; Pred R2: 0.9847; Adeq precision: 52.0918.
2982 Proc IMechE Part C: J Mechanical Engineering Science 237(13)

Table 10. Analysis of variance analysis for the clad width of CrNiW clad powder.

Source of Sum of Degrees of Mean F-value p-Value Source

variation squares freedom squares

Model 0.1116 9 0.0124 6.4572 0.0441 Significant

A-Laser power 0.0153 1 0.0153 7.9734 0.0476
B-Speed 0.0152 1 0.0152 7.9143 0.0482
C-Feed rate 0.0586 1 0.0586 30.4972 0.0053
AB 0.0002 1 0.0002 0.1503 0.7179
AC 0.0076 1 0.0076 3.9707 0.1171
BC 0.0028 1 0.0028 1.4618 0.2932
A2 0.0107 1 0.0107 5.6094 0.077
B2 0.0017 1 0.0017 0.905 0.3953
C2 0.0022 1 0.0022 1.1727 0.3397
Residual 0.0076 4 0.0019
Lack of fit 0.0076 3 0.0025 50.9078 0.1026 Not significant
Error 5 3 10205 1 5 3 10205
Corrected total 0.1193 13

R2: 0.9356; Adj R2: 0.7907; Pred R2: 20.0253; Adeq precision: 7.6401.

Table 11. Analysis of variance analysis for the clad depth of CrNiW clad powder.

Source of Sum of Degrees of Mean F-value p-Value Source

variation squares freedom squares

Model 3.2551 9 0.3616 717.53 \ 0.0001 Significant

A-Laser power 3.0187 1 3.0187 5988.9 \ 0.0001
B-Speed 0.103 1 0.103 204.36 0.0001
C-Feed rate 0.0056 1 0.0056 11.261 0.0284
AB 0.0018 1 0.0018 3.5918 0.131
AC 4.35 3 10205 1 4.35 3 10205 0.0864 0.7834
BC 0.0006 1 0.0006 1.225 0.3304
A2 0.1188 1 0.1188 235.86 0.0001
B2 2.92 3 10205 1 2.92 3 10205 0.058 0.8214
C2 0.0011 1 0.0011 2.3402 0.2008
Residual 0.002 4 0.0005
Lack of fit 0.0018 3 0.0006 3.027 0.3943 Not significant
Error 0.0002 1 0.0002
Corrected total 3.2571 13

R2: 0.9993; Adj R2: 0.9979; Pred R2: 0.9908; Adeq precision: 76.7082.

ANOVA shown in Table 7 for the clad width of Cladheight= +0:745+0:020xA  0:025xB
CrNiFeAlZr powder indicates that laser beam power +0:161xC  0:0005xAxB+0:0003xAxC
(A), scanning speed (B), feed rate of clad powder (C),
0:047xBxC+0:047xA2 +0:067xB2 0:109xC2
A2 and B2 are significant model terms. The ‘Pred R2’
of 0.9112 is in good agreement with the ‘Adj R2’ of ð1Þ
0.9778. The model is significant with a Model F-value
of 64.7848. A ‘lack of fit F-value’ of 1.01 implies that Cladwidth= +2:47+0:043xA  0:139xB
there is no significant relationship between the lack of
+0:052xC  0:013xAxB  5x10  05xAxC+
fit and the pure error. There’s a 60.70% risk that noise
will cause a big ‘lack of fit p-value’. 0:019xBxC+0:109xA2 +0:0702xB2 +0:0299xC2
Instead, the ANOVA shown in Table 8 for the clad ð2Þ
depth of CrNiFeAlZr powder shows that laser beam
power (A), scanning speed (B) and A2 are significant
Claddepth=+0:491+0:064xA0:074xB
terms. The ‘Pred R2’ of 0.3566 and the ‘Adj R2’ of
0.8681 are in functional agreement. The model has a 0:027xC0:021xAxB0:0057xAxC
Model F-value of 10.51, indicating that it is significant. +0:0148xBxC0:064xA2 0:023xB2 0:048xC2
The lack of fit F-value of 28.92 suggests that it is not
ð3Þ
significant. There’s a 13.56% risk that noise will cause a
big ‘lack of fit p-value’. The regression model developed
for the clad height, width and depth of CrNiFeAlZr The ANOVA shown in Table 9 for the clad height of
powder is shown in equations (1)–(3), respectively. CrNiW powder indicates that laser power (A);
Martin Vinoth and Dinesh Babu 2983

scanning speed (B); feed rate (C) and interactions BC, speed, and then it increases when the scanning speed
A2, B2 and C2 are significant terms. The ‘Pred R2’ of is more than 650 mm/min. With the rise of laser beam
0.9847 is in good agreement with the ‘Adj R2’ of power at a lower scanning speed, the clad height
0.9965. The F-value of 420.64 for the model suggests decreases gradually and then increase rapidly when
that it is significant. A ‘lack of fit F-value’ of 2.18 the laser power is over 2.1 kW. With a faster scanning
implies that the lack of fit has no bearing on the pure speed, less metal powder is injected into the substrate,
error. There is a 45.28% risk that noise will cause a resulting in a thinner coating layer. More metal pow-
big ‘lack of fit p-value’. der floods the substrate as the powder feed rate is
The ANOVA Table 10 for the clad width of increased. The amount of powder coating put on the
CrNiW powder indicates that laser power (A), scan- substrate increases, absorbing more laser energy in
ning speed (B), feed rate (C) are important terms. The the process. As a result, more energy is expended to
F-value of 6.46 for the model suggests that it is very melt the metal powder rather than the substrate,
significant. The 50.91 ‘lack of fit F-value’ suggests resulting in a thin but high cladding bead.
that the lack of fit is not substantial in comparison to Figure 16(b) displays the effect of laser beam power
the pure error. A large ‘lack of fit p-value’ owing to and scanning speed in which the laser power increases
noise has a 10.26% chance of occurring. With a nega- the clad depth gradually for all different scanning
tive ‘Pred R2’, the total mean is a better predictor of speeds, and the maximum clad depth is obtained for
response than the current model. a lower scanning speed of 500 mm/min for a laser
The ANOVA shown in Table 11 for the clad depth beam power of 2.5 kW. Figure 16(c) shows that the
of CrNiW powder indicates that laser beam power increased scanning speed for different laser powers
(A), scanning speed (B), powder feed rate (C) and A2 decreases the clad width. When the scanning speed
are significant terms. The model is significant with an rises, the heat input reduces due to less contact time
F-value of 717.54. A 3.03 ‘lack of fit F-value’ shows of the laser beam with the material. The laser beam
that the lack of fit is not substantial when compared power influences the clad width more than the scan-
to the pure error. A large ‘lack of fit p-value’ due to ning speed. The three-dimensional surface plots, as
noise has a 39.43% chance of happening. With a ‘Adj shown in Figure 16(d), represent the varying influence
R2’ of 0.9979, a ‘Pred R2’ of 0.9908 is in reasonable of the laser beam power and scanning speed on clad
agreement. A ratio of 76.708 indicates an adequate height. At a lower laser beam power, the clad height
signal. The regression model developed for clad tends to drop rapidly with the rise in scanning speed,
height, width and depth of CrNiW powder is shown and then it increases when the scanning speed is
in equations (4)–(6) respectively. above 650 mm/min. With the rise in laser beam power
at a lower scanning speed, the clad height decreases
Cladheight=+0:75+0:014xA0:031xB steadily and then it increases rapidly when the laser
+0:182xC0:0023xAxB0:0001xAxC beam power is over 2.1 kW.
0:0292xBxC+0:061xA2 +0:041xB2 0:1175xC2 In Figure 16(e) the surface plot demonstrates the
influence of laser beam power, and scanning speed of
ð4Þ clad powder on clad depth. When the laser power
increases for all scanning speed ranges, the clad depth
Cladwidth= +2:35+0:043xA0:043xB also increases due to more heat input at higher power
+0:085xC0:008xAxB0:043xAxC+ and induces more depth of penetration of clad powder
into the base metal. when the scanning speed increases
0:026xBxC+0:058xA2 +0:023xB2 +0:026xC2
(see Figure 16(f)), the clad width reduces rapidly. The
ð5Þ maximum clad width was achieved for a power of
2.5 kW a low scanning speed.
Claddepth= +1:296+0:614xA0:113xB
0:026xC0:0212xAxB+0:0033xAxC Optimisation of clad parameters
0:0124xBxC0:19xA2 +0:003xB2 0:019xC2 Importance varied from minimum important
ð6Þ ( + + + ), that is, a value of 3, to maximum impor-
tant ( + + + + + ), that is, a value of 5. For each
response, most importance was considered, and the
Interaction effects of process parameters on responses for weight value given for all responses is 1. The optimi-
CrNiFeAlZr and CrNiW powders. When an interaction sation criteria for CrNiW and CrNiFeAlZr powders
consequence of any two factors is inspected, the addi- utilised in this investigation are presented in Tables 12
tional factors are retained at their mid-value. and 13. In this, all variables were retained in the
Figure 16(a) illustrates the varying effects of laser range, and the clad width was kept at maximum level
beam power and scanning speed on the clad height. and other responses at minimum level.
At a lower laser beam power, the clad height tends to The top 10 solutions obtained through optimisa-
decrease quickly with an increase in the scanning tion are presented in Tables 14 and 15 for CrNiW
2984 Proc IMechE Part C: J Mechanical Engineering Science 237(13)

Figure 16. Interaction effects of laser power and scanning speed on responses for CrNiFeAlZr and CrNiW powders at a constant
powder feed rate of 10 g/min: (a) clad height for CrNiFeAlZr, (b) clad depth for CrNiFeAlZr, (c) clad width for CrNiFeAlZr, (d) clad
height for CrNiW, (e) clad depth for CrNiW and (f) clad width for CrNiW.

Table 12. Optimisation criteria for CrNiW powder.

Factor/response Goal Lower limit Upper limit Lower Upper Importance

weight weight

Laser beam power (kW) Is in range 1.7 2.5 1 1 3

Scan speed (mm/min) Is in range 500 800 1 1 3
The feed rate of clad Is in range 8 12 1 1 3
powder (g/min)
Clad height (mm) Minimise 0.4856 0.9286 1 1 5
Clad width (mm) Maximise 2.2312 2.5652 1 1 5
Clad depth (mm) Minimise 0.4195 1.8368 1 1 5
Martin Vinoth and Dinesh Babu 2985

Table 13. Optimisation criteria for CrNiFeAlZr powder.

Factor/response Goal Lower Upper Lower Upper Importance

limit limit weight weight

Laser beam power (kW) Is in range 1.7 2.5 1 1 3

Scan speed (mm/min) Is in range 500 800 1 1 3
The feed rate of clad Is in range 8 12 1 1 3
powder (g/min)
Clad height (mm) Minimise 0.5011 0.9492 1 1 5
Clad width (mm) Maximise 2.2231 2.7242 1 1 5
Clad depth (mm) Minimise 0.2562 0.5969 1 1 5

Table 14. Optimisation solutions for CrNiW powder.

Exp. Cladding parameters Response value Desirability

Laser power Scanning speed Powder feed Clad height Clad width Clad depth
(kW) (mm/min) rate (g/min) (mm) (mm) (mm)

1 1.733 799.996 12 0.841 2.532 0.419 0.737 Selected

2 1.733 798.758 12 0.841 2.532 0.419 0.737
3 1.733 797.14 12 0.841 2.532 0.42 0.737
4 1.732 795.901 12 0.841 2.531 0.419 0.737
5 1.732 794.019 12 0.84 2.531 0.42 0.737
6 1.731 791.324 12 0.84 2.531 0.419 0.737
7 1.731 789.987 12 0.84 2.531 0.419 0.737
8 1.729 784.286 12 0.84 2.53 0.419 0.737
9 1.728 799.365 12 0.842 2.534 0.407 0.737
10 1.729 783.173 12 0.84 2.53 0.419 0.737

Table 15. Optimisation solutions for CrNiFeAlZr powder.

Exp. Cladding parameters Response value Desirability

Laser beam Scanning speed Powder feed Clad height Clad width Clad depth
power (kW) (mm/min) rate (g/min) (mm) (mm) (mm)

1 1.7 594.193 8 0.502 2.562 0.359 0.778 Selected

2 1.7 592.185 8 0.503 2.564 0.36 0.778
3 1.7 596.389 8 0.502 2.561 0.358 0.778
4 1.7 595.611 8 0.502 2.561 0.359 0.778
5 1.7 589.531 8 0.503 2.565 0.361 0.778
6 1.7 587.505 8 0.504 2.566 0.361 0.778
7 1.7 608.564 8 0.501 2.553 0.354 0.777
8 1.7 609.913 8 0.5 2.552 0.354 0.777
9 1.7 572.753 8 0.508 2.574 0.366 0.776
10 1.7 610.983 8 0.5 2.551 0.353 0.776

and CrNiFeAlZr, respectively. At all times, high parametric values were chosen with the highest desir-
desirability is preferred. In total, 10 solutions were ability of 0.778. The related present optimal process
generated for receiving a true optimal solution, and parameter settings of 1.7 kW of laser power,
the most satisfactory solution was achieved based on 594.193 mm/min of scanning speed and 8.0 g/min of
desirability. clad powder feed rate were considered for
For multi-response optimisation difficulty, optimal CrNiFeAlZr.
input parametric values were selected with the highest To achieve the desired clad geometry, the desirabil-
desirability of 0.737; the corresponding optimal pro- ity approach method was applied for deciding the
cess parameter settings of 1.733 kW of laser power, optimum input process parameters. The validation
799.996 mm/min of scanning speed and 12 g/min of tests were also carried out from the optimum input
clad powder feed rate were considered for CrNiW. process parameters. There was excellent concord
For multi-response optimisation, the optimal input between the measured and predicted values. The
2986 Proc IMechE Part C: J Mechanical Engineering Science 237(13)

Table 16. Validation test results for CrNiW and CrNiFeAlZr.

Alloy powder Responses Predicted Desirability Experimental Error

(mm) (%)

CrNiW Height 0.8409 0.737 0.8610 2.39

Width 2.5321 0.737 2.5512 0.75
Depth 0.4193 0.737 0.4211 0.43
CrNiAlFeZr Height 0.5024 0.778 0.5140 2.30
Width 2.5622 0.778 2.5915 1.14
Depth 0.3590 0.778 0.3610 0.55

Figure 17. SEM micrographs laser clad specimens: (a) CrNiFeAlZr clad (1.7 kW, 594 mm/min and 8 g/min) and (b) CrNiW clad
(1.7 kW, 799 mm/min and 12 g/min).

results of validation tests for CrNiW and 1. Both CrNiW and CrNiFeAlZr claddings were
CrNiFeAlZr contrast are given in Table 16. free of flaws such as pores and cracks and had
The percentage of error between the predicted good metallurgical bonding with the base mate-
value and the actual value is less than 2.5%, which is rial. The homogenous structure of the coating
in the acceptable range. The acquired result demon- was demonstrated by element distribution.
strates that the experimental measurements are in 2. The grain sizes of CrNiW and CrNiFeAlZr pow-
concurrence with the predicted measurements. ders after cladding are 4 and 17 mm, respectively.
Therefore, it can be established that optimal para- The interface thickness between the substrate
meters are achieved by RSM with high accuracy. and CrNiW clad and between the substrate and
The validation test was carried out from the set of CrNiFeAlZr clad is ~2 and ~7 mm, respectively.
generated solutions and also, the SEM micrographs The grain size and interface thickness difference
for the two different powders CrNiFeAlZr and between the two types of cladding with their sub-
CrNiW, as shown in Figure 17(a) and (b). strates are due to the effect of different alloying
Figure 17(a) shows elongated coarse grains in the powder compositions.
laser-clad zone (CrNiFeAlZr); in contrast, fine grains 3. After laser cladding, the powders are dispersed
are illustrious in CrNiW clad zone as shown in uniformly along the surface, which is evident from
Figure 17(b). the thickness analysis, and the average thickness
of the clad profile was 924.42 mm for CrNiW clad
and 952.34 mm for CrNiFeAlZr clad.
Conclusion
4. The average microhardness obtained in the clad
A study of laser cladding process of CrNiW and surface is 834 6 20 and 780 6 20 HV0.5 for
CrNiFeAlZr on H13 tool steel substrate was con- CrNiW and CrNiFeAlZr, respectively, which is
ducted. The interaction effect of laser clad input vari- higher than the base hardness of 548 6 20 HV0.5.
ables was analysed and optimum process variables In the interface region, the hardness is slightly
were obtained. The following results can be drawn higher in the clad region for both the clad
from this investigation: powders.
Martin Vinoth and Dinesh Babu 2987

5. The common phase formation of Ni3C and Fe3C ORCID iD

for CrNiFeAlZr and CrNiW coatings were iden- P Dinesh Babu https://orcid.org/0000-0002-9606-3289
tified from the XRD patterns, and oxide forma-
tion was found only in CrNiFeAlZr coating. At
high temperatures, the Al2O3 layer significantly References
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temperature oxidation resistance of H13 steel by laser List of abbreviations
cladding with a WC/Co-Cr alloy coating. Anti Corros AISI American Iron and Steel Institute
Methods Mater 2016; 63: 171–176.
ANOVA Analysis of variance method
32. Huang SW, Samandi M and Brandt M. Abrasive wear
BBD Box-Behnken design
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layers. Wear 2004; 256: 1095–1105. CCA Complex concentrated alloy
33. Yao F, Fang L and Chen X. Geometry analysis and CPM Crucible particle metallurgy
microhardness prediction of nickel-based laser cladding DoE Design of experiments
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408–419. HAZ Heat affected zone
Martin Vinoth and Dinesh Babu 2989

JEOL Japan electron optics laboratory SEM-EDS Scanning electron microscopy-energy

PCE Powder catchment efficiency dispersive X-ray spectroscopy
RSM Response surface methodology XRD X-ray diffractometer