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Laser Cladding
Laser Cladding
Ehsan Toyserkani
Amir Khajepour
Stephen Corbin
CRC PR E S S
Boca Raton London New York Washington, D.C.
Library of Congress Cataloging-in-Publication Data
Catalog record is available from the Library of Congress
This book contains information obtained from authentic and highly regarded sources. Reprinted material
is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable
efforts have been made to publish reliable data and information, but the author and the publisher cannot
assume responsibility for the validity of all materials or for the consequences of their use.
Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic
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© 2005 by CRC Press LLC
No claim to original U.S. Government works
International Standard Book Number 0-8493-2172-7
Printed in the United States of America 1 2 3 4 5 6 7 8 9 0
Printed on acid-free paper
Dedications
Ehsan Toyserkani
To my father and mother, who taught me to learn. To my beloved wife and
son, Homeyra and Ali, who have truly brought joy in my life.
Amir Khajepour
To my son and wife for the joy and comfort you have given to my life, and
my family for your support.
Stephen Corbin
To the memory of my sister, Pamela Corbin, who was an enthusiastic and
passionate teacher for over 20 years. Pamela inspired my own interest in the
field
of education which ultimately led to my academic career.
© 2005 by CRC Press LLC
Preface
Laser cladding by powder injection has received significant attention in re-
cent years due to its unique features and capabilities in various industries
involved in metallic coating, high-value components repair, prototyping, and
low-volume manufacturing. This emerging laser material processing technique
is an interdisciplinary technology utilizing laser technology, computer-aided
design and manufacturing (CAD/CAM), robotics, sensors and control, and
powder metallurgy and rapid solidification. Further development of this tech-
nique depends on enhancement of the technologies involved and understanding
the interconnections among these technologies and the process quality.
A good comprehension of the underlying physics of the laser cladding process
is key in the development of the process as a reliable coating and manufactur-
ing technology. In addition to a good grasp of feedback control and automa-
tion, a strong knowledge of material science, heat transfer, and
fluid
dynamics
is essential to a successful development of an automated laser cladding system.
The intent of this book is to address the lack of a comprehensive book
dealing with the di erent aspects of laser cladding. The authors have used the
results of their own research and experience in the past few years along with
the
findings
of many other researchers in the preparation of this book. The
book provides a solid and detailed description of laser cladding in modeling,
materials, and control and can be used in both academia and industry.
The book begins with a review of the applications of laser cladding, and
continues with physical descriptions of the process and the parameters in-
volved, process modeling and control, process applications, and the physical
metallurgy of alloying and solidification during laser cladding. We illustrate
the general principles of the technique with several case studies based on a
number of important common laser cladding applications. Extensive refer-
ences to the current literature have also been provided to guide the reader to
further information on desired topics.
We are very much indebted to many colleagues and students for their help
in the preparation of this book. Special thanks go to Professors David Weck-
man, Walter Duley and Jan Huissoon of the University of Waterloo for their
valuable comments. We are grateful to Dr. Ste en Nowotny of the Fraunhofer
Institute for Material and Beam Technology, Dr. Lijue Xue of the Integrated
Manufacturing Technologies Institute (IMTI) of National Research Council
of Canada (NRC), Dr. Frank Arcella of AeroMet Cooperation, Dr. Joohyun
Choi of University of Missouri at Rolla, Mr. David Gill of Sandia National
Laboratories, and Mr. Michael Kardos of Optomec Inc. for providing us
© 2005 by CRC Press LLC

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