Multiphysics Simulation and Experimental Analysis of Laser-Clad Stellite 6 on 316 Stainless Steel Using FEM and RSM

Multiphysics Simulation and Experimental Analysis of Laser-Clad Stellite 6 on 316 Stainless Steel Using FEM and RSM | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Multiphysics Simulation and Experimental Analysis of Laser-Clad Stellite 6 on 316 Stainless Steel Using FEM and RSM sayed hamid hashemi, Reza Shoja Razavi, Reza Vafaei, Amin Nourollahi This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7450826/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This research explores how process parameters affect the molten pool formation and solidification structure during the laser cladding of Stellite 6 onto a 316 stainless steel substrate. The study combines Finite Element Method (FEM) simulations with empirical-statistical approaches. Using the Response Surface Method (RSM), the Design of Experiments (DOE), optimization, validation, and statistical modeling were carried out. FEM was utilized to simulate and analyze heat distribution generated during the laser cladding process. The FEM model, within an Arbitrary Lagrange-Eulerian (ALE) framework, included material selection, determination of thermal properties, substrate dimensions and meshing, boundary condition application, heat flux input, and temperature-dependent equations for specific heat, thermal conductivity, and density. Thermal analysis and 3D temperature distribution indicated that the molten pool began forming 0.51 seconds after the laser was activated and grew as heat input increased. The peak temperature was reached 0.2 seconds after the laser beam struck the substrate. Simulated and experimental data for single-pass cladding showed acceptable correlation, with 78% and 80.5% prediction accuracy for height and width, respectively. The calculated thermal gradient (G) ranged from 100 to 750 K/mm, and the solidification rate (R) varied from 0.001 to 0.009 m/s. The developed regression models demonstrated strong predictive capabilities, with R² values of 0.90, 0.99, 0.98, and 0.97 for clad height, width, penetration depth, and dilution, respectively. The optimization process yielded a desirability score of 0.795, while experimental validation confirmed the model's reliability, with a maximum prediction error of 13%. Laser Cladding Finite Element Method Stellite 6 Stainless Steel 316 Heat Transfer Solidification Response Surface Methodology (RSM) Full Text Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7450826","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":521443503,"identity":"1a77b184-13ee-4e51-9ff4-29406f4c3508","order_by":0,"name":"sayed hamid 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