Performance of Laser-Clad Repairs on Steel Plates with Different Simulated Corrosion Defects

Laser cladding technology can be used to repair corroded steel structures, where machining is commonly employed to simulate corrosion defects. However, the repair effectiveness for chemically corroded interfaces remains to be investigated. In this study, notched steel specimens were prepared using a hybrid method combining mechanical milling followed by electrochemical corrosion, as well as direct mechanical milling. Laser cladding was then applied for repair, and a comparative analysis of tensile properties and microstructural characteristics was conducted between repaired and unrepaired specimens. Tensile tests showed that specimens prepared by both corrosion simulation methods exhibited comparable postrepair mechanical properties, with yield strength and ultimate tensile strength similar to that of noncorroded specimens. The cladding layer in repaired specimens yielded later due to its high strength, which also restrains the plastic deformation of the substrate in the repaired zone, enabling coordinated deformation between the cladding and substrate. In contrast, the unrepaired region yielded earlier with faster strain accumulation, leading to necking fracture. No defects, such as pores or cracks, were observed in either type of repaired specimen, and residual products from electrochemical corrosion had no significant effect on cladding interface bonding. Laser cladding effectively repaired both electrochemically corroded and mechanically milled steel plates. Considering corrosion time and notch geometry requirements, mechanically milled specimens can be used for experimental studies.