Abstract
Laser cladding performance is strongly controlled by process parameters, making their optimization essential for achieving high-quality deposits. This study employed a laser power ramp-up technique as a rapid screening method to evaluate multiple processing conditions along a single deposited bead. The effects of laser power, travel speed, defocusing distance, and wire feed rate on clad geometry were investigated to minimize dilution, penetration depth, and wetting angle while maximizing the aspect ratio (width/height). The results showed that laser power had a significant influence on bead geometry and track quality. Optimal conditions were obtained with lower laser power, lower travel speed, higher defocusing distance, and higher wire feed rate, resulting in a dilution of approximately 14.3%, corresponding to about 17.6% Fe in the fusion zone. These findings demonstrate that the laser power ramp-up technique provides an efficient approach for process parameter optimization in wire laser cladding.