Optimization of Multi-Track Laser Cladding Process Parameters for Fe-Cr-Ni Wear-Resistant Coatings via RSM-MOPSO

The surface of nodular cast iron is susceptible to wear failure under high-load conditions. In this study, Fe-Cr-Ni wear-resistant coatings were developed on the surface of nodular cast iron using laser cladding technology. The influence of laser power (P), powder feeding rate (F), scanning speed (V), and overlapping rate (φ) on the microhardness and dilution rate of the coatings was analyzed by response surface methodology, while the model’s accuracy was evaluated through analysis of variance. Subsequently, the multi-objective particle swarm optimization algorithm was utilized to identify the optimal process parameters (P = 1350 W, V = 12.5 mm/s, F = 9 g/min, and φ = 45%) based on non-destructive testing results. The predictive model values closely matched the experimental results. The average microhardness of the Fe-Cr-Ni cladding layer was 620.3 HV, which was 2.8 times that of the nodular cast iron substrate. Importantly, the laser cladding layer demonstrated a significant improvement in wear resistance compared to the substrate. The wear mechanisms for the coating predominantly involved mild abrasive wear and adhesive wear, while the substrate primarily experienced severe adhesive wear. This study offers valuable insights for optimizing laser cladding process parameters for nodular cast iron.