Temperature and composition profile during double-track laser cladding of H13 tool steel

Abstract

Multi-track laser cladding is now applied commercially in a range of industries such as automotive, mining and aerospace due to its diversified potential for material processing. The knowledge of temperature, velocity and composition distribution history is essential for a better understanding of the process and subsequent microstructure evolution and properties. Numerical simulation not only helps to understand the complex physical phenomena and underlying principles involved in this process, but it can also be used in the process prediction and system control. The double-track coaxial laser cladding with H13 tool steel powder injection is simulated using a comprehensive three-dimensional model, based on the mass, momentum, energy conservation and solute transport equation. Some important physical phenomena, such as heat transfer, phase changes, mass addition and fluid flow, are taken into account in the calculation. The physical properties for a mixture of solid and liquid phase are defined by treating it as a continuum media. The velocity of the laser beam during the transition between two tracks is considered. The evolution of temperature and composition of different monitoring locations is simulated.

Numerical simulation of thermal behavior and multicomponent mass transfer in direct laser deposition of Co-base alloy on steel

“…However, a large number of trial experiments are time-consuming and money-consuming. Numerical simulation has offered an effective tool in prediction the thermal behavior and mass transport in direct laser deposition [11][12][13][14][15][16][17][18][19][20][21][22]. A three-dimensional mathematical model has been established in which the temperature field and flow field is obtained [11].…”

“…The dualequation of mass transfer was utilized to calculate separately the composition profile between deposited layer and base metal. He et al [20,21] proposed a 3D transient heat and mass transfer model to predict the solute distribution in the deposited layer. The mathematical model was calculated by solving the species conservation equations besides the energy and momentum conservation equations.…”

“…The binary system Fe-C and Fe-Cr were evaluated to obtain the concentration distribution of C and Cr [20]. The solute transfer and composition profiles evolution for binary system Fe-C during double-track direct metal deposition also have been reported [21]. Although the multicomponent mass transfer model has been built in metal casting and chemical engineering [22,23], such study for direct laser deposition has not been reported in the open peerreviewed literature.…”

Flow characteristics of metallic powder grains for additive manufacturing

“…Thus, the powder interacts strongly with the the fluid dynamics of the shielding gas, that effects crucially the trajectory of single powder particles and hence, its location of deposition. Numerical approaches developed by He et al [2], Peyre et al [3], Wen et al [4] and Qi et al [5] describe the fusion process, however, neglect the transport of powder between nozzles and substrate. Therefore, the objective of the current contribution is to describe numerically the complex process of powder deposition on a substrate.…”

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

“…In previous work, He and Mazumder mainly investigated the heat transfer, fluid flow and energy distribution during single-track laser cladding [1], and the temperature and composition profile of the overlap region for double-track laser cladding [28]. In this study, the solute transport and composition profile evolution by single track during coaxial laser cladding is simulated by a selfconsistent three dimensional numerical model, in which some important physical phenomena including melting and solidification, phase changes, mass addition, and interactions between the laser beam and the coaxial powder flow are considered.…”