Skip to main content
SpringerLink
Log in

Powder flow simulation of a ring-type coaxial nozzle and cladding experiment in laser metal deposition

  • Application
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

A 3D full size numerical model of a ring-type coaxial nozzle was established to obtain particle space trajectory and convergence character. The realizable k-ε model was applied in the gas flow phase. The powder flow was coupled with the gas flow by using Euler–Lagrange approach as a discrete phase model. Different powder material and particle sizes were selected to calculate the powder concentration distribution. The simulated powder stream morphology matched well with the experimental results of high-speed camera observations. Simulation results showed that using mean diameter \(\overline{\mathrm{d} }\) to replace Rosin–Rammler distribution of particle size could get accurate flowing characteristic results. Simulation results also showed that this substitution could save computational resources and reduce the computing time significantly. The presence of the coaxial shielding gas has direct impact on the powder mass concentration spatial distribution, maximum value convergence height, and spot size of the powder flow. For 316L with small particle size and Ni60A with large particle size, we found different change regularities and no linear relationship was found. Therefore, it is recommended not to change the input volume of coaxial shielding gas without special needs. Simulation results, combining with the laser cladding experiments of Ni60A, have demonstrated that the developed ring-type coaxial nozzle could transport powder efficiently and form excellent deposited layers. The conditional powder utilization ratio can be as good as 75.9%.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Availability of data and material

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

References

  1. Tamanna N, Crouch R, Naher S (2019) Progress in numerical simulation of the laser cladding process. Opt Lasers Eng 122:151–163. https://doi.org/10.1016/j.optlaseng.2019.05.026

    Article  Google Scholar 

  2. Li L, Huang Y, Zou C, Tao W (2021) Numerical study on powder stream characteristics of coaxial laser metal deposition nozzle. Curr Comput-Aided Drug Des 2021(11):282. https://doi.org/10.3390/cryst11030282

    Article  Google Scholar 

  3. Li C, Zhang D, Yang Y, Gao H, Han X (2021) Research on sputtering behavior of three beams coaxial laser cladding powder based on the interaction of lasers and powder. J Laser Appl 33(4):042020. https://doi.org/10.2351/7.0000449

  4. Zhu G, Li D, Zhang A, Tang Y (2011) Numerical simulation of metallic powder flow in a coaxial nozzle in laser direct metal deposition. Opt Laser Technol 43(1):106–113. https://doi.org/10.1016/j.optlastec.2010.05.012

    Article  Google Scholar 

  5. Arrizubieta JI, Tabernero I, Ruiz JE, Lamikiz A, Martinez S, Ukar E (2014) Continuous coaxial nozzle design for lmd based on numerical simulation. Phys Procedia 56(56):429–438. https://doi.org/10.1016/j.phpro.2014.08.146

    Article  Google Scholar 

  6. Tabernero I, Lamikiz A, Ukar E, De Lacalle LL, Angulo C, Urbikain G (2010) Numerical simulation and experimental validation of powder flux distribution in coaxial laser cladding. J Mater Process Technol 2010(210):2125–2134. https://doi.org/10.1016/j.jmatprotec.2010.07.036

    Article  Google Scholar 

  7. Liu Z, Qi H, Jiang L (2016) Control of crystal orientation and continuous growth through inclination of coaxial nozzle in laser powder deposition of single-crystal superalloy. J Mater Process Technol 2016(230):177–186. https://doi.org/10.1016/j.jmatprotec.2015.11.017

    Article  Google Scholar 

  8. Zhang J, Yang L, Li Z, Zhang Q, Yu M, Fang C, Xiao H (2021) Transport phenomenon, flow field, and deposition forming of metal powder in the laser direct deposition with designed nozzle. Int J Adv Manuf Technol 114(1). https://doi.org/10.1007/s00170-021-06913-x

  9. Kovalev OB, Zaitsev AV, Novichenko D, Smurov I (2011) Theoretical and experimental investigation of gas flows, powder transport and heating in coaxial laser direct metal deposition (DMD) process. J Therm Spray Technol 20:465–478. https://doi.org/10.1007/s11666-010-9539-3

    Article  Google Scholar 

  10. Hua T, Fengying Z, Xin Fu, Jian M, Guang Hu, Wei F, Huang W (2016) Development of powder flow model of laser solid forming by analysis method. The International Journal of Advanced Manufacturing Technology. https://doi.org/10.1007/s00170-015-7481-8

    Article  Google Scholar 

  11. Popovich A, Sufiiarov V, Polozov I, Borisov E, Masaylo D, Orlov A (2016) Microstructure and mechanical properties of additive manufactured copper alloy. Mater Lett 179:38–41. https://doi.org/10.1016/j.matlet.2016.05.064

  12. Higashino R, Sato Y, Masuno S, Shobu T, Funada Y, Abe N, Tsukamoto M (2020) Development of blue diode laser for additive manufacturing. Laser 3D Manufacturing VII. https://doi.org/10.1117/12.2543119

  13. Fan J, Zhao H, Cen K (1992) An experimental study of two-phase turbulent coaxial jets. Exp Fluids 1992(13):279–287. https://doi.org/10.1007/BF00189021

    Article  Google Scholar 

  14. Fluent Inc. (2018) FLUENT 19.0 User Guide

  15. Kim SE, Choudhury D, Patel B (1999) Computations of complex turbulent flows using the commercial code fluent. In: Salas M.D., Hefner J.N., Sakell L. (eds) Modeling Complex Turbulent Flows. ICASE/LaRC Interdiscip Ser Sci Eng 7. Springer, Dordrecht. https://doi.org/10.1007/978-94-011-4724-8_15

  16. Shih TH, Liou WW, Shabbir A, Yang Z, Zhu J (1994) A New k-(Eddy viscosity model for high reynolds number turbulent flows - model development and validation. Comput Fluids 24

  17. Gosman AD, Ioannides E (2022) Aspects of computer simulation of liquid-fuelled combustors

  18. Thomy C, Seefeld T, Vollertsen F (2008) Humping effect in welding of steel with single-mode fibre laser. Welding in the World 52.5–6(2008):9–18. https://doi.org/10.1007/BF03266636

  19. Tong X, Li F, Liu M, Dai M, Zhou H (2010) Opt Laser Technol 42:1154

    Article  Google Scholar 

  20. Steen WM (1998) Laser Materials Processing, second edition. Springer

  21. Zekovic S, Dwivedi R, Kovacevic R (2007) Numerical simulation and experimental investigation of gas–powder flow from radially symmetrical nozzles in laser-based direct metal deposition. Int J Mach Tools Manuf 47(1):112–123. https://doi.org/10.1016/j.ijmachtools.2006.02.004

    Article  Google Scholar 

  22. Yang N (2009) Concentration model based on movement model of powder flow in coaxial laser cladding. Opt Laser Technol 41:94–98. https://doi.org/10.1016/j.optlastec.2008.03.008

    Article  Google Scholar 

  23. Zhang J, Yang L, Zhang W, Qiu JB, Xiao HB, Yang L (2020) Numerical simulation and experimental study for aerodynamic characteristics and powder transport behavior of novel nozzle. Opt Lasers Eng 126:105873. https://doi.org/10.1016/j.optlaseng.2019.105873

    Article  Google Scholar 

  24. Hemmati I, Ocelík V, De Hosson JTM (2011) The effect of cladding speed on phase constitution and properties of AISI 431 stainless steel laser deposited coatings. Surf Coat Technol 205.21(2011):5235–5239. https://doi.org/10.1016/j.surfcoat.2011.05.035

  25. Fs A, Wang TA, Ll A, Yz A, Wei WB, Sw B (2020) Effect of microstructure on the corrosion resistance of coatings by extreme high speed laser cladding. Appl Surf Sci. https://doi.org/10.1016/j.apsusc.2020.146085

    Article  Google Scholar 

  26. Chen Z, Li R, Gu J, Zhang Z, Tao Y, Tian Y (2019) Laser cladding of ni60 + 17 4ph composite for a cracking-free and corrosion resistive coating. Int J Mod Phys B 34(1n03):2040042. https://doi.org/10.1142/S0217979220400421

Download references

Funding

This work was funded by Guangdong Province Key Field Research and Development Program Project (2020B090924002), National Natural Science Foundation of China (U2001218), Guangdong Province Joint Key Fund of Guangdong and Shenzhen (2020B151520013), and Guangdong Province Basic and Applied Basic Research Fund Project (2019B1515120094).

Author information

Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, 510640, China

    Heng Zhou, Yongqiang Yang, Di Wang, Yang Li, Shiqin Zhang & Zhiheng Tai

Authors
  1. Heng Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yongqiang Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Di Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Shiqin Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Zhiheng Tai
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Conceptualization, H.Z., Y.Y., S.Z., Y.L., D.W., Z.T. Data curation, H.Z., Y.L., D.W., G.D., Z.T. Form analysis, H.Z., D.W., Y.L. Funding acquisition, Y.Y. Investigation, D.W., H.Z., Y.L. Methodology, H.Z., D.W., Y.L. Project administration, Y.Y. Supervision, S.Z., D.W. Writing, original draft, H.Z. Writing, review and editing, D.W., Y.L., H.Z.

Corresponding authors

Correspondence to Yongqiang Yang or Yang Li.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

Not applicable.

Conflicts of interest

The authors declare there no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhou, H., Yang, Y., Wang, D. et al. Powder flow simulation of a ring-type coaxial nozzle and cladding experiment in laser metal deposition. Int J Adv Manuf Technol 120, 8389–8400 (2022). https://doi.org/10.1007/s00170-022-09175-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09175-3

Keywords

Search

Navigation