A predictive laser hardening model for industrial parts with complex geometric features has been developed and used for optimization of hardening processes. A transient three-dimensional thermal model is combined with a three-dimensional kinetic model for steel phase transformation and solved in order to predict the temperature history and solid phase history of the workpiece while considering latent heat of phase transformation. Further, back-tempering is also added to the model to determine the phase transformation during multitrack laser hardening. The integrated model is designed to accurately predict temperature, phase distributions and hardness inside complex geometric domains. The laser hardening parameters for two industrial workpieces are optimized for two different industrial laser systems using this model. Experimental results confirm the validity of predicted results.

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