A Numerical Study on Metallic Powder Flow in Coaxial Laser Cladding

In coaxial laser cladding, the quality and property of deposition products are greatly influenced by the powder flow, which is responsible to transport additive materials to the deposition point on a substrate precisely. The metallic powder flow in coaxial laser cladding is simulated by a numerical model based on the gas-solid flow theory. The characteristics of powder concentration distribution between coaxial nozzle and deposition point for a kind of nickel based alloy powder are studied by the proposed model. The relationship between the process parameters and powder flow characteristics, such as focus distance from the nozzle exit and maximum powder concentration, is analyzed to optimize the powder feeding process. In addition, the influence of substrate with different surface shapes on the powder flow is investigated. The results can be used as a guideline for the location of the substrate and the selection of proper processing parameters for coaxial laser cladding

Numerical simulation of powder transport behavior in laser cladding with coaxial powder feeding

Laser cladding with coaxial powder feeding is one of the new processes applied to produce well bonding coating on the component to improve performance of its surface. In the process, the clad material is transported by the carrying gas through the coaxial nozzle, generating gas-powder flow. The powder feeding process in the coaxial laser cladding has important influence on the clad qualities. A 3D numerical model was developed to study the powder stream structure of a coaxial feeding nozzle. The predicted powder stream structure was well agreed with the experimental one. The validated model was used to explore the collision behavior of particles in the coaxial nozzle, as well as powder concentration distribution. It was found that the particle diameter and restitution coefficient greatly affect the velocity vector at outlet of nozzle due to the collisions, as well as the powder stream convergence characteristics below the nozzle. The results indicated a practical approach to optimize the powder stream for the coaxial laser cladding.</p