Process parameter optimization of WC/Inconel 625 metal matrix composites laser cladding based on the Taguchi approach and NSGA-II algorithm

This paper focuses on optimizing the laser cladding process parameters of WC/Inconel 625 composite on a low-carbon steel substrate. This process aims to improve industrial parts’ wear and corrosion properties in corrosive and high-temperature environments. Laser power, laser cladding speed, powder-feeding rate, and WC content percentage were process input parameters, each at three levels. The dilution ratio and micro-hardness of samples were considered as process responses. Taguchi orthogonal arrays were employed for experimental design, and the results were analyzed using signal-to-noise ratio and analysis of variance. A linear regression model was developed to understand the relationship between process parameters and responses. In addition, two-objective optimization of the process parameters using the second-generation non-dominated sorting genetic algorithm (NSGA-II), and a hybrid algorithm based on the multi-objective whale optimization algorithm (MOWOAGA) were carried out to determine the optimal parameters that minimize the dilution ratio and maximize the cladding hardness. The results showed that the laser power and the powder-feeding rate have the most excellent effect on the dilution ratio. In contrast, WC content percentage and powder-feeding rate strongly affect micro-hardness. Based on the applied meta-heuristic algorithms and confirmed by experimental tests, the laser power of 370 W, laser cladding speed of 4 mm/s, powder-feeding rate of 8 g/min, and WC content percentage of 20.5% are the most optimal process parameters that lead to micro-hardness of 397 Vickers and dilution percentage of 2.5%. This research guides selecting, controlling, and optimizing WC/Inconel 625 composite laser cladding process parameters.