Optimisation of Response Surface Methodology Based on Finite Element Analysis for Laser Cladding of Highly Hardened WC(Co,Ni) Coatings

In the present work, the optimization of ceramic-based composite WC(Co,Ni) welds by laser cladding was carried out using response surface methodology based on finite element analysis. The heat distribution and temperature field of laser-melted WC(Co,Ni) ceramic coatings were simulated using ANSYS software, which allowed the computation of the distribution of residual stresses. The results show that the isotherms in the simulation of the temperature field are elliptical in shape, and that the isotherms in front of the moving heat source are dense with a larger temperature gradient, while the isotherms behind the heat source are sparse with a smaller temperature gradient. In addition, the observed microstructural evolution shows that the melting zone domains of WC(Co,Ni) are mainly composed of unmelted carbides. These carbides are dendritic, rod-like, leaf-like, or net-like, and are agglomerated into smaller groups. The W content of these unmelted carbides exceeds 80%, while the C content is around 1.5–3.0%. The grey areas are composed of WC, Co and Ni compounds. Based on the regression model, a quadratic model was successfully constructed. A three-dimensional profile model of the residual stress behaviour was further explored. The estimated values of the RSM-based FEA model for residual stress are very similar to the actual results, which shows that the model is effective in reducing residual stress by laser cladding.