Laser-assisted wire cladding using a retrofitted laser welding system

Laser-assisted wire cladding has emerged as a popular method for the surface modification and repair of components as it provides cleaner processing environments, reduced costs with higher material deposition rates, and better surface finish. However, the high capital cost of laser cladding systems can be detrimental to their adoption in industry. This work presents a favourable option for industry by using a traditional 6 kW Ytterbium-doped fibre laser welder retrofitted with a MIG welder wire-feeding system to obtain laser cladded surfaces without specialized laser cladding equipment. A high dynamic range camera is used to observe material deposition modes, which influence the coating and surface quality. Process-related mechanisms are proposed to explain the observed deposition modes, along with an analysis of the process parameters that influence the clad characteristics. By carefully selecting the process parameters in this non-traditional laser cladding option, defect-free depositions with good surface finish can be achieved.