A theoretical model for laser and powder particles interaction during laser cladding

Fu, Yunchang; Loredo, Alexandre; Martin, Bruno; Vannes, A.B.

doi:10.1016/s0924-0136(02)00433-8

Cited by 113 publications

(34 citation statements)

References 10 publications

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“…When advancing from one time step to the next, some of the particles reach the z ¼ 0 plane and transfer all of their absorbed energy to the melt pool. Assuming that the energy which was absorbed by the particle during its flight is evenly distributed over the particle 10 and neglecting the losses due to convection and radiation with the surroundings, 11 the absorbed particle energy is transferred to the sensor as a disk with a uniform energy distribution. Combining the energy of all the particles that reach the workpiece results in an additional energy pattern that can be averaged over time.…”

Section: Ray-tracing Proceduresmentioning

confidence: 99%

“…However, when determining the effect of the flow on the laser beam energy, several assumptions are typically introduced such as the simplification of the powder flow to a statistical particle density distribution and neglecting particle reflections and shadow overlaps. 5,[8][9][10][11][12] This paper presents a ray-tracing method which is able to calculate the effect of the powder flow on the laser energy distribution without the need for these assumptions.…”

Section: Introductionmentioning

confidence: 99%

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Modeling of laser beam and powder flow interaction in laser cladding using ray-tracing

Devesse

Baere

Guillaume

2015

Journal of Laser Applications

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Laser cladding, also known as direct metal deposition, is an additive manufacturing technique for the production of freeform metallic parts. In the laser cladding process, a high-power laser beam is directed onto the surface of a solid metallic workpiece while a jet of metallic powder is focused into the beam through a coaxial nozzle. The heating of the workpiece is governed by the laser light that is being absorbed, so that detailed simulations of the laser cladding process require an accurate knowledge of the light intensity pattern that reaches the workpiece after interaction with the powder jet. In the past, several statistical distributions have been proposed for modeling this intensity pattern. However, these require strong simplifications of the powder particle trajectories and do not take into account the complex powder flow profile that is present in practical systems. In this paper, the effect of the powder flow on the incident laser intensity is numerically studied under varying process conditions. A finite element simulation of the powder flow is performed and used to generate a set of powder particle trajectories using Monte Carlo simulation. A ray-tracing algorithm is developed to split the laser beam into multiple rays of light which get partly reflected and absorbed by the particles and the workpiece. Running the ray-tracing procedure over time allows the calculation of an averaged incident light intensity pattern as well as an averaged pattern of the energy absorbed by the particles that arrive at the workpiece. Several simulations are performed in order to study the effects of the used laser intensity pattern and the particle size distribution. The results are in good agreement with existing literature. V C 2015 Laser Institute of America. [http://dx

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Section: Ray-tracing Proceduresmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Modeling of laser beam and powder flow interaction in laser cladding using ray-tracing

Devesse

Baere

Guillaume

2015

Journal of Laser Applications

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“…2. the powder particles are spherical and uniformly distributed in the powder stream, 3. energy loss by convection and radiation is negligible (Fu et al, 2002), 4. the effect of gravity and the drag exerted by the surrounding gas on particle movement are negligible and all particles have the same velocity, 5. the shadow effect of the particles on each other is accounted for, 6. the fraction of the laser beam energy absorbed by a particle is given by the absorptivity of the particle material ( ) for the laser radiation wavelength, 7. the temperature distribution in each particle is uniform, 8. latent heat effects due to melting are neglected (Anandkumar et al, 2009). As the interaction time (t) is given by d/v p , where d is the distance traveled by the particle through the laser beam and v p its projected velocity component, Eq.…”

Section: Laser Surface Cladding Of Aluminium Alloysmentioning

confidence: 99%

Laser Surface Treatments of Aluminum Alloys

Razavi¹,

Gordani²

2011

Recent Trends in Processing and Degradation of Aluminium Alloys

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“…Attenuation of laser power during interaction between a laser and powder was investigated a lot [2][3][4][5][6][7][8][9][10][11][12][13][14][15]. Qi et al [2] considered the coaxial laser powder interaction while modelling heat transfer and fluid flow during DMD.…”

Section: Introductionmentioning

confidence: 99%

“…It was found that the powder catchment efficiency and the beam energy redistribution in the material can be optimized by the powder mass flow rate and geometrical properties of the beam and powder jet. An analytical model was presented by Fu et al [11], in which a powder injection angle was introduced to enable the analysis for both coaxial and lateral powder flows. Formulations for divergent or attenuated laser beams were also given in their model for possible analytical solutions of attenuated energy distribution.…”

Section: Introductionmentioning

confidence: 99%

Solute transport and composition profile during direct metal deposition with coaxial powder injection

Song

et al. 2011

Applied Surface Science

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a b s t r a c tDirect metal deposition (DMD) with coaxial powder injection allows fabrication of three-dimensional geometry with rapidly solidified microstructure. During DMD, addition of powder leads to the interaction between laser and powder, and also the redistribution of solute. The concentration distribution of the alloying element is very important for mechanical properties of the deposited clad material. The evolution of concentration distribution of carbon and chromium in the molten pool is simulated using a selfconsistent three-dimensional model, based on the solution of the equations of mass, momentum, energy conservation and solute transport in the molten pool. The experimental and calculated molten pool geometry is compared for model validation purposes.

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A theoretical model for laser and powder particles interaction during laser cladding

Cited by 113 publications

References 10 publications

Modeling of laser beam and powder flow interaction in laser cladding using ray-tracing

Modeling of laser beam and powder flow interaction in laser cladding using ray-tracing

Laser Surface Treatments of Aluminum Alloys

Solute transport and composition profile during direct metal deposition with coaxial powder injection

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