Development and application of laser cladding modeling technique: From coaxial powder feeding to surface deposition and bead formation

O. B. Kovalev, D. V. Bedenko, A. V. Zaitsev

Research output: Contribution to journalArticlepeer-review

34 Citations (Scopus)

Abstract

A numerical modeling technique is developed for the processes of coaxial laser gas-powder cladding occurring in additive technologies for the manufacture of complex geometry objects. The model is based on a three dimensional (3D) description of mutually related problems of gas dynamics, powder transport, laser heating, and thermal processes in the clad bead and substrate, which are considered without convection in the melt pool. The results of gas-disperse flow modeling with a triple coaxial nozzle are presented. Analysis of bead profiles on a flat substrate with variation in operating parameters is carried out. It is revealed that a self-consistent and practically reasonable model can be obtained when the considered processes are described in а mathematically conjugate 3D formulation. Comparison of the calculated bead profiles and experimental data (for the powder mixture with 16NCD13 steel and titanium carbide TiC) shows a good qualitative and quantitative correlation. In addition, regularities of the modeled repeated beam scanning and production of overlapped profiles of the beads lying beside each other on the flat substrate are discussed.

Original languageEnglish
Pages (from-to)339-359
Number of pages21
JournalApplied Mathematical Modelling
Volume57
DOIs
Publication statusPublished - 1 May 2018

Keywords

  • Bead profile formation
  • Coaxial powder transportation
  • Heat transfer
  • Laser cladding
  • Multi-path deposition
  • Numerical modeling
  • Powder utilization factor
  • BEHAVIOR
  • NOZZLE
  • SUPERALLOY
  • SMOOTH
  • DIRECT METAL-DEPOSITION
  • FLOW
  • PREDICTION
  • TRANSPORT
  • NUMERICAL-SIMULATION
  • GEOMETRY

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