A finite element method approach for thermal analysis of laser cladding of magnesium alloy with preplaced Al–Si powder

A numerical model based on the finite element method (FEM) has been developed to simulate the temperature profile of laser cladding with preplaced metal powders. The FEM model is capable of simulating the three-dimensional thermal field of the cladding zone under the condition of a moving heat source, taking into consideration the thermal contact resistance between the powder bed and the substrate. Verification experiments were conducted by the laser cladding of Al–12%Si alloy on ZM51 magnesium alloy, using a high-power Nd:yttrium–aluminum–garnet laser. The results show that the model can be employed to determine the appropriate processing parameters for achieving good interfacial bonding between the clad layer and the substrate. On the other hand, the model shows that under the normal cladding conditions, significant dilution would occur in laser cladding of magnesium alloys.