Numerical simulation and experimental investigation of the effect of three-layer annular coaxial shroud on gas-powder flow in laser cladding

Lyu, Peijie; Jin, Ling; Yan, Binggong; Li, Zhu; Ye, Jun; Jiang, Kaiyong

doi:10.1016/j.jmapro.2022.10.019

Cited by 6 publications

(2 citation statements)

References 36 publications

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“…The continuous phase flow behavior requires the solution of a set of Navier-Stokes equations [19]. The turbulent nature of gas-powder flow necessitates the consideration of the Reynolds-Averaged Navier-Stokes (RANS) equation when solving for the flow behavior of gas, as it temporally averages both the velocity field and pressure field [18,20].…”

Section: Continuous Phase Modelingmentioning

confidence: 99%

Optimization of process parameters for gas-powder flow behavior in the coaxial nozzle during laser direct metal deposition based on numerical simulation

Zhao,

Yang,

Chen

et al. 2024

Int J Adv Manuf Technol

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Laser direct metal deposition (DMD) can supply a new method in the fields of surface modification and near-net forming. The powder flow behavior and its convergence characteristics play a crucial role in the deposition quality during the DMD process. In this research, the k-ε turbulence model based on the Computational Fluid Dynamics (CFD) modeling method was innovatively employed to establish the numerical model of the gas-powder flow. Then, the Dense Discrete Phase Model (DDPM) was utilized in this gas-powder coupling model to accurately calculate the collision between particles and between particle and inner wall of the nozzle. Afterward, the Response Surface Method (RSM) was carried out to design the numerical simulation scheme, analyze a series of simulation results, explore the correlation between the process parameters and the responses, and establish the prediction model of powder convergence characteristics. Furthermore, the process parameters were optimized by considering the influence of defocusing amount, with smaller powder spot diameter and higher maximum powder mass concentration as optimization objectives. It was found that the prediction model of responses demonstrated a high degree of accuracy and reliability. The single deposition track exhibited better deposition quality fabricated with the optimized process parameters. The research method and results mentioned in the present study were expected to provide significant theoretical guidance for the selection and application of process parameters during the laser direct metal deposition process.

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Section: Continuous Phase Modelingmentioning

confidence: 99%

Optimization of process parameters for gas-powder flow behavior in the coaxial nozzle during laser direct metal deposition based on numerical simulation

Zhao,

Yang,

Chen

et al. 2024

Int J Adv Manuf Technol

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show abstract

“…In 2022, Lyu et al designed a three-layer annular coaxial shield (TACS) using computational methods, analyzed the powder feeding process using Euler-Lagrange, and established a gaspowder computational fluid dynamics (CFD) four-flow nozzle model. The results show that when the velocity of the inner gas and carrier gas of TACS is equal, the powder flow exhibits the optimal concentration in the molten pool [12]. In summary, the numerical model of gas-powder two-phase flow during laser cladding has formed a relatively complete theoretical system, but in the study of particle flight characteristics, the discussion of the randomness of particle size distribution is brief.…”

Section: Introductionmentioning

confidence: 99%

Investigation on the Interaction Law between Laser and Powder and Multi-Field Coupling Mechanism during Laser Cladding under Different Elevation Angles

Sun,

Li,

Han

et al. 2024

Preprint

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During laser cladding under different elevation angles, there is an interaction between the waist beam and the laser energy. The interaction law is complicated, involving many physical and chemical processes such as laser energy absorption, powder melting, evaporation and solidification. It is a bottleneck problem in the industry to quantitatively reveal the interaction law between laser and powder during cladding, which is significant to improve the cladding quality. In this paper, a continuous-discrete phase gas/solid coupling model of laser and powder interaction during laser cladding under different elevation angles was established. In the modeling, the random distribution of 316L powder with different particle sizes was realized through Rosin-Rammler-Sperling curve fitting, and a custom UDF cone heat source program was written to calculate and reveal the temperature, concentration and flow velocity of powder with random particle size distribution during cladding under different elevation angles. The effects of different elevation angles of laser head on powder convergence and laser powder interaction were quantified. On this basis, the multi-field coupling numerical model of laser cladding process under different elevation angles was established, and its transient evolution was revealed. The calculation shows that the powder temperature, concentration, flow velocity and cladding layer height of 15° elevation angle are more in line with the process requirements, and the convergence of powder reaching the substrate is better. Finally, the temperature of the cladding process was collected by infrared thermal imaging camera, and the cladding profile was compared and analyzed to verify the effectiveness of the model.

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Effects of different Y compounds on the microstructure and properties of laser cladding NiTi coatings in a semi-open environment

Cui

Guo

et al. 2023

Intermetallics

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Numerical simulation and experimental investigation of the effect of three-layer annular coaxial shroud on gas-powder flow in laser cladding

Cited by 6 publications

References 36 publications

Optimization of process parameters for gas-powder flow behavior in the coaxial nozzle during laser direct metal deposition based on numerical simulation

Optimization of process parameters for gas-powder flow behavior in the coaxial nozzle during laser direct metal deposition based on numerical simulation

Investigation on the Interaction Law between Laser and Powder and Multi-Field Coupling Mechanism during Laser Cladding under Different Elevation Angles

Effects of different Y compounds on the microstructure and properties of laser cladding NiTi coatings in a semi-open environment

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