Optimization of Titanium Alloy Surface Enhancement via Laser Cladding Using Grey Relational Analysis

Laser cladding on titanium alloys is a fundamental method for enhancing surface qualities and is necessary for applications needing strong mechanical strength and wear resistance. This paper explores the influence of laser power, speed, and gas flow rate on titanium substrates cladded with Satellite 22 powder. Using a Taguchi L₉ orthogonal array, the experimental design examined the impacts of these factors on hardness and thickness under support from microstructural and phase evaluations by SEM and XRD examinations. Surface hardness exhibited a notable improvement in values reaching up to three-fold increases and thickness displaying evident dependant on laser speed. SEM analysis verified good homogenous alloying element distribution and metallurgical bonding. XRD measurements indicated many phases generating better mechanical characteristics. Grey relational analysis (GRA) multi-response optimisation successfully incorporated many performance criteria and identified the ideal parameter values to optimise general quality. Results demonstrated a significant increase in surface hardness up to a threefold improvement with hardness values in the cladded layer between 450 and 550 HV. Given their strong correlation with laser speed, thickness fluctuations proved to be very crucial in layer deposition. SEM investigation demonstrated a homogenous and continuous distribution of alloying components, therefore confirming good metallurgical connection between the cladded layer and the substrate. Many phases found within the cladded material by XRD helped to explain their better mechanical characteristics.