A dual-frequency electromagnetic sensor for non-contact dilution evaluation in laser cladding and alloying processes

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Abstract
In laser surface cladding and alloying processes, the properties of the cladding/alloy layer produced may change due to dilution by the substrate. At the same time the thickness of the cladding/alloy layer may vary. A dual-frequency electromagnetic sensor has been developed to enable the simultaneous, non-contact, non-destructive measurement of the magnetic reluctance of the workpiece and air gaps. This has been applied to monitoring the level of dilution (the degree of contamination by substrate) in laser cladding/alloying processes. For certain types of cladding/substrate combinations such as those having large differences either in magnetic permeability or in conductivity, the sensor can indicate the level of dilution of the cladding/alloy. The effects of magnetic flux leakage, edge fringing, eddy currents, cladding/alloy thickness, surface temperature, operating frequency and signal processing are discussed. Both theoretical analysis and experimental data are presented. Good agreement between the theory and experiments has been achieved.

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