Numerical Simulation of Laser Cladding Using Cable Wires

Cable wires provide a viable technical pathway for the laser additive manufacturing of high-entropy alloys (HEAs). However, the complex interplay of structural and material parameters of cable wires leads to significant variations in molten pool dynamics, which poses challenges to the fabrication of high-quality HEA coatings. To clarify the effects of these key factors on molten pool behavior, a multi-physics numerical model for the laser cladding of Al₅₀Si₆Ti₈Cr₁₂Cu₁₂Ni₁₂ cable wires was established in this study. A dedicated physical model for cable wires was developed, and the Level Set Method was employed to track fluid interfaces throughout the cladding process. Based on the proposed model, the temperature distribution, stress fields, and elemental homogeneity within the molten pool were systematically investigated. The results reveal that chromium (Cr) addition induces a viscosity reduction, and a torsional pitch of ≤4 mm is critical for achieving defect-free, compositionally uniform HEA coatings, which provides novel insights for process optimization and alloy design of cable-wire laser cladding.