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Numerical simulation and experimental investigation of gas-powder flow feed behavior in laser cladding with coaxial nozzle

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Abstract

The utilization of powders is the main factor determining the cost of laser-cladding industrial applications. The work established a 3D numerical model of gas-powder two-phase flow in the coaxial powder-feeding process to understand the gas-powder flow stream characteristics and improve the utilization of powders and the forming efficiency. The verified model was used to analyze the influences of the distance between the nozzle and substrate, carrier-gas flow rate, and powder feeding voltage on powders’ concentration on the substrate, cladding morphology, and powders’ utilization efficiency. The results showed that 9.5 mm was the optimal working distance of the nozzle, with the highest powder concentration on the substrate and the highest powder utilization rate. Appropriately increasing the gas flow rate was conducive to gathering powder particles; however, the increased gas flow rate aggravated particles to spray outwards and reduced the powder concentration on the substrate. After powder-feeding gas flow rate GF = 8 NL/min, the focused powder diameter no longer decreased. At this time, the cladding area was the maximum with the highest utilization rate of powders. As the powder feeding voltage increased, the cladding area and the utilization rate of powders increased. This model can accurately predict the transportation and concentration of powders on the substrate, which provides theoretical guidance for efficient forming by laser cladding.

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Funding

The work was supported by the Program for Innovative Research Team in Science and Technology in Fujian Province University.

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Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, Fujian University of Technology, Fuzhou Fujian, 350118, China

    Mengya Chu, Guofu Lian, Meiyan Feng, Changrong Chen & Xu Huang

  2. Research Center for Advanced Manufacturing, Lyle School of Engineering, Southern Methodist University, 3101 Dyer Street, Dallas, TX, 75205, USA

    Mingpu Yao

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  1. Mengya Chu
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  2. Guofu Lian
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  4. Meiyan Feng
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  5. Changrong Chen
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  6. Xu Huang
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Contributions

All authors contributed to the work’s conception and design. Material preparation, data collection, and analysis were performed by Mengya Chu, Guofu Lian, Mingpu Yao, Meiyan Feng, Changrong Chen, and Xu Huang. The first draft of the manuscript was written by Mengya Chu, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Guofu Lian or Mingpu Yao.

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Chu, M., Lian, G., Yao, M. et al. Numerical simulation and experimental investigation of gas-powder flow feed behavior in laser cladding with coaxial nozzle. Int J Adv Manuf Technol 122, 881–894 (2022). https://doi.org/10.1007/s00170-022-09768-y

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  • DOI: https://doi.org/10.1007/s00170-022-09768-y

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