Integrated statistical modelling and process optimization of laser cladding of IN625 on Rene 125 turbine blade using advanced correlation analysis
Year: 2025
Type: article
Abstract: This study investigates the influence of critical laser cladding parameters(laser power (P), scan speed (V), and powder feed rate (F))on the geometric characteristics of IN625 single-pass tracks deposited on the constrained surface (∼1.6 mm width) of Rene 125 turbine blades, diverging from conventional research typically conducted on flat plate substrates. A full factorial design systematically varied P (200–350 W), V (5–11 mm/s), and F (0–250 mg/s) to fabricate 36 single-pass tracks. Comprehensive cross-sectional analysis via SEM, integrated with advanced Pearson correlation analysis, evaluated key responses: track width (W), height (H), penetration depth (b), dilution (D), and wetting angle (T). Quadratic polynomial models achieved R 2 values of 0.65–0.83, confirming adequate predictive accuracy while underscoring the process complexity. Pearson correlations revealed unconventional trends distinct from flat-surface studies: laser power exhibited a significant negative correlation with track width (r ≈ −0.43) but a positive correlation with wetting angle (r ≈ 0.34). Scan speed positively influenced W while reducing H, whereas elevated powder feed rates increased H (r ≈ 0.51) yet decreased D (r ≈ −0.57) and b (r ≈ −0.49). These findings highlight the unique interplay of parameters in turbine blade repair contexts, where geometric constraints alter conventional process dynamics. Through multi-response optimization, the optimal parameter set(275 W, 8 mm/s, and 150 mg/s) was identified to achieve precise geometric control, balancing dimensional accuracy and metallurgical integrity essential for aerospace component restoration.
Institution: Malek Ashtar University of Technology
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,640
OpenAlex ID: W7082966652