Fluid Flow and Stress Field During Laser Cladding-Based Surface Repair of Aluminum Alloy: Multi-Track Simulation

Laser cladding (LC) is a promising technique for repairing aluminum alloy components, yet challenges like cracks and uneven surfaces persist due to unstable melt flow and thermal stress. This study employs both fluid flow and stress field models to investigate multi-track LC repair mechanisms. Using a finite volume method (FVM), the dynamic evolution of the molten pool was quantified, revealing a maximum flow velocity of 0.2 m/s, a depth of 0.7 mm, and a width of 4 mm under optimized parameters (1600 W laser power, 600 mm/min scan speed). The model also identified that surface flaws between 300 and 900 μm were fully melted and repaired by a current or adjacent track. Finite element analysis (FEA) showed that multi-layer cladding induced a cumulative thermal stress exceeding 1300 MPa at interlayer interfaces, necessitating ≥ 3 s cooling intervals to mitigate cracking risks. These findings provide critical insights into process optimization, demonstrating that adjusting laser power and scan speed can control molten pool stability and reduce residual stress, thus improving repair quality for aluminum alloys.