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<p>To investigate the molten pool dynamics and defect formation mechanisms during the laser cladding of FeCoNiCrMo high-entropy alloys on Ti6Al4V substrates, a three-dimensional coupled temperature and flow field model for a single-track cladded coating was established. The influence of varying laser energy densities (80, 90, 100, 110, and 120&#xa0;J/mm<sup>2</sup>) on the geometric characteristics of the cladded coating was systematically analyzed to elucidate the relationship between processing parameters and cladding morphology. The results reveal that the presence of pronounced Marangoni convection significantly influences the morphological characteristics of the FeCoNiCrMo cladded coating. At a laser energy density of 120&#xa0;J/mm<sup>2</sup>, the molten pool flow velocity reaches up to 48&#xa0;mm/s, leading to the maximum observed values of cladded layer dimensions. Conversely, at a lower energy density, the molten pool demonstrates limited flowability and promotes bubble entrapment at the solidification front and contributes to the formation of porosity defects. Elevated laser energy densities (Led = 110 and 120&#xa0;J/mm<sup>2</sup>) were observed to enhance the dilution rate of the cladded coatings, thereby promoting the diffusion of alloying elements from the molten pool into the Ti6Al4V substrate. However, the increased energy input also led to higher residual tensile stresses within the cladded coatings, which serve as a driving factor for crack initiation at the fusion interface between the substrate and cladded materials.</p>

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Preparation of FeCoNiCrMo High-Entropy Alloy Coatings by Laser Cladding on Ti6Al4V Surface: Study on Molten Pool Dynamic Behavior and Defect Initiation

  • 期刊论文

  • 发表日期：

    2025年10月28日

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  • Jitai Han,
  • Chen Cui,
  • Dadong Jie,
  • Yin Li,
  • Kui Zhu,
  • Yanan Ge,
  • Sida Tang,
  • Weiming Ma,
  • Jiahui Guan,
  • Peng Li

摘要

To investigate the molten pool dynamics and defect formation mechanisms during the laser cladding of FeCoNiCrMo high-entropy alloys on Ti6Al4V substrates, a three-dimensional coupled temperature and flow field model for a single-track cladded coating was established. The influence of varying laser energy densities (80, 90, 100, 110, and 120 J/mm2) on the geometric characteristics of the cladded coating was systematically analyzed to elucidate the relationship between processing parameters and cladding morphology. The results reveal that the presence of pronounced Marangoni convection significantly influences the morphological characteristics of the FeCoNiCrMo cladded coating. At a laser energy density of 120 J/mm2, the molten pool flow velocity reaches up to 48 mm/s, leading to the maximum observed values of cladded layer dimensions. Conversely, at a lower energy density, the molten pool demonstrates limited flowability and promotes bubble entrapment at the solidification front and contributes to the formation of porosity defects. Elevated laser energy densities (Led = 110 and 120 J/mm2) were observed to enhance the dilution rate of the cladded coatings, thereby promoting the diffusion of alloying elements from the molten pool into the Ti6Al4V substrate. However, the increased energy input also led to higher residual tensile stresses within the cladded coatings, which serve as a driving factor for crack initiation at the fusion interface between the substrate and cladded materials.