Thermo-fluid flow behavior of the IN718 molten pool in the laser directed energy deposition process under magnetic field

Abstract

Purpose This paper aims to understand the magnetohydrodynamics (MHD) mechanism in the molten pool under different modes of magnetic field. The comparison focuses on the Lorenz force excitation and its effect on the melt flow and solidification parameters, intending to obtain practical references for the design of magnetic field-assisted laser directed energy deposition (L-DED) equipment. Design/methodology/approach A three-dimensional transient multi-physical model, coupled with MHD and thermodynamic, was established. The dimension and microstructure of the molten pool under a 0T magnetic field was used as a benchmark for accuracy verification. The interaction between the melt flow and the Lorenz force is compared under a static magnetic field in the X-, Y- and Z-directions, and also an oscillating and alternating magnetic field. Findings The numerical results indicate that the chaotic fluctuation of melt flow trends to stable under the magnetostatic field, while a periodically oscillating melt flow could be obtained by applying a nonstatic magnetic field. The Y and Z directional applied magnetostatic field shows the effective damping effect, while the two nonstatic magnetic fields discussed in this paper have almost the same effect on melt flow. Since the heat transfer inside the molten pool is dominated by convection, the application of a magnetic field has a limited effect on the temperature gradient and solidification rate at the solidification interface due to the convection mode of melt flow is still Marangoni convection. Originality/value This work provided a deeper understanding of the interaction mechanism between the magnetic field and melt flow inside the molten pool, and provided practical references for magnetic field-assisted L-DED equipment design.

Design of dissimilar material joint for defect-free multi-material additive manufacturing via laser-directed energy deposition

“…This obstruction hinders powder jetting, causing the molten metal to flow downward and stretch the surface in contact with the obstacle due to adhesion. The surface in contact with the base metal contracts upon solidification, while other surfaces contract due to surface tension [ [28] , [29] , [30] , [31] ]. Consequently, pores form between the different metals due to convection flow within the molten metal.…”

Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts

“…However, the brush plating coating is shallow, the strength of the bond is low, there is a large residual stress generated, and the coating easily falls off [ 7 ]; the spraying process itself is low strength, not up to the strength of the metal itself, and the spraying layer will produce certain porosity, flow hanging, bubbles, unevenness and other problems [ 8 , 9 ]. However, laser cladding is a directional energy deposition (DED) technology [ 10 , 11 ], the principle of which is to use a high-energy density laser beam to metallurgically bond the powder to the substrate, with fast cooling and fast heating, which can improve the surface properties of the substrate material, making it stronger, have better wear resistance, higher thermal fatigue strength, etc. [ 12 , 13 , 14 ].…”