Laser Metal Deposition (LMD) & Directed Energy Deposition (DED) Utility
Laser Cladding & DED Bead Overlap Calculator
Calculate track stepover pitch, bead overlap %, deposited layer thickness, specific energy density (J/mm²), powder consumption, and continuous hatch toolpath geometry for industrial hardfacing and additive manufacturing.
1. Cladding & Beam Parameters
Fiber/Diode laser output
Melt pool beam width
Linear cladding velocity
Distance between adjacent tracks
Mass flow from powder feeder
Percentage captured in melt pool
Area width
Area length
2. Overlap & Deposition Results
Track Bead Overlap
50.0 %
Optimal range: 45% to 55%
Layer Thickness
0.98 mm
Mean single pass build height
Specific Energy Density
55.6 J/mm²
P / (D × V) Heat input rating
Coverage Rate
10.8 cm²/min
Surface area deposition speed
Dilution & Quality Assessment
Optimal (Dilution < 5%, Zero Interpass Porosity)
50% overlap provides flat surface waviness and sound metallurgical bond.
Cross-Sectional Clad Bead Profile
3 Tracks @ 1.5mm Pitch
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Laser Cladding Mathematical Principles
In Laser Cladding and Direct Energy Deposition (DED), powder is injected coaxially into a laser melt pool. Key physical relationships govern layer quality:
Overlap (%) = [ 1 - (Stepover Pitch / Spot Diameter) ] × 100
Specific Energy (J/mm²) = Laser Power (W) / [ Spot Diameter (mm) × Travel Speed (mm/s) ]
Layer Thickness (mm) = [ Powder Feed (g/s) × Efficiency ] / [ Stepover (mm) × Speed (mm/s) × Alloy Density (g/cm³) ] × 1000
- Optimal Overlap Range (45% – 55%): If overlap is < 40%, severe valleys form between tracks (high surface roughness and inter-pass lack-of-fusion voids). If overlap is > 65%, excessive remelting causes high thermal distortion and high base-metal dilution.
- Low Dilution Control (< 5%): Unlike arc welding (GMAW/PTA) which dilutes up to 20–30% with the base steel, precision laser cladding maintains < 5% dilution, preserving the pure corrosion and wear resistance of Stellite or Inconel in a single pass.