Optimization of Direct Laser Deposition of a Martensitic Steel Powder (Metco 42C) on 42CrMo4 Steel

In this study, the deposition of martensitic stainless-steel (Metco 42C) powder on 42CrMo4 structural steel by direct laser deposition (DLD) was investigated. Clads were produced by varying the laser power, scanning speed, feed rate, and preheating. The effect of these processing variables on the microstructure and microhardness of the clads was analyzed, as well as their soundness, yield (measured by dilution), and geometric characteristics (height, width, and depth). The complex interaction of the evaluated processing variables forced the application of complex parameters to systematize their effect on the clads. A genetic optimization algorithm was performed to determine the processing conditions warranting high-quality clads, that is, sound clads, metallurgically bonded to the substrate with required deposition yield.