Additive & Cladding Engineering
DED Arc & Plasma Hardfacing Overlap & Dilution Calculator
Model linear heat input ($HI$), dilution ratio ($D\%$), stepover pitch ($p$), and deposition coverage rate for PTA powder and wire arc hardfacing overlays.
1. Input Parameters
Thermal transfer efficiency dictates net linear heat input into substrate.
Standard hardfacing overlap is 45% - 55% to ensure planar wear surfaces.
Lower penetration reduces dilution with mild steel base metal.
2. Calculation Results
Linear Heat Input ($HI$)
1.02 kJ/mm
Stepover Pitch ($p$)
8.00 mm
Dilution Percentage ($D\%$)
17.4 %
Area Coverage Rate
22.4 cm²/min
3. Dynamic Visualizer & CAM Preview
4. Engineering Notes & Physics Specifications
Direct Energy Deposition (DED) Arc and Plasma Transferred Arc (PTA) hardfacing require strict control of dilution percentage ($D\%$) and track overlap pitch ($p$) to achieve maximum abrasive, erosive, and impact wear resistance without cracking.
- Linear Heat Input Formula:
HI = η · (V · I · 60) / (v · 1000)in kJ/mm. Controlling heat input prevents thermal distortion, excessive grain growth, and heat-affected zone (HAZ) micro-fissuring. - Dilution Calculation:
D% = (p_sub / (p_sub + h_clad)) × 100%. In PTA tungsten carbide (WC-Co/NiCrBSi) cladding, dilution is maintained below 5%–12%, whereas in FCAW/GMAW it typically ranges from 15%–30%. - Stepover Pitch ($p$):
p = W × (1 - Overlap%/100). Overlap between 45% and 55% eliminates scalloped valleys and creates a flat deposit requiring minimal post-weld grinding. - Continuous Serpentine CAM: Vector toolpaths must include tangent arc lead-in loops and continuous bidirectional rasters to avoid arc start crater cracks.
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