A low-parameter dimensionless model and dimensional analysis for predicting melt pool geometry in laser cladding

The process parameters have a crucial impact on the formation of the melt pool during laser cladding (LC), significantly affecting the quality of the cladding layer. While predictive models for melt pool geometry are indispensable for optimizing coating production, existing models are often hampered by a reliance on numerous fitting parameters, limiting their practical utility. This study introduces a novel dimensionless model that dramatically reduces this complexity by incorporating only four key fitting parameters: relative melt pool area, aspect ratio, relative laser power, and powder mass flow rate. Multi-physics numerical simulations have been completed to elucidate the influence of process parameters on melt pool dynamics and validate the effectiveness. The results showed that the dimensionless model achieved excellent agreement with numerical and experimental results (R²=0.76-0.90, error