Modelling Powder Concentration Distribution From a Coaxial Deposition Nozzle for Laser-Based Rapid Tooling

Pinkerton, Andrew J.; Li, Lin

doi:10.1115/1.1643748

Cited by 126 publications

(83 citation statements)

References 23 publications

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“…The obtained flow field is in good agreement with the theoretical and experimental results obtained by other authors in the field. 7,8 Particle trajectories were generated by injecting the particles into the outer nozzle inlet and simulating their motion over time. The particles are made of Stainless steel AISI 316 L with the material parameter values of Table I.…”

Section: Resultsmentioning

confidence: 99%

“…However, when determining the effect of the flow on the laser beam energy, several assumptions are typically introduced such as the simplification of the powder flow to a statistical particle density distribution and neglecting particle reflections and shadow overlaps. 5,[8][9][10][11][12] This paper presents a ray-tracing method which is able to calculate the effect of the powder flow on the laser energy distribution without the need for these assumptions.…”

Section: Introductionmentioning

confidence: 99%

“…A large amount of literature can be found on the physical modeling of the heat conduction and liquid flow processes in the workpiece, [2][3][4] as well as on the numerical investigation of the gas and powder flows that exit the nozzle. [5][6][7][8] This paper focuses on the latter modeling aspect by studying the effect of the powder flow on the laser energy distribution that reaches the surface of the workpiece. In previous literature, detailed calculations of the powder flow have been performed and experimentally verified for different nozzle geometries.…”

Section: Introductionmentioning

confidence: 99%

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Modeling of laser beam and powder flow interaction in laser cladding using ray-tracing

Devesse

Baere

Guillaume

2015

Journal of Laser Applications

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Laser cladding, also known as direct metal deposition, is an additive manufacturing technique for the production of freeform metallic parts. In the laser cladding process, a high-power laser beam is directed onto the surface of a solid metallic workpiece while a jet of metallic powder is focused into the beam through a coaxial nozzle. The heating of the workpiece is governed by the laser light that is being absorbed, so that detailed simulations of the laser cladding process require an accurate knowledge of the light intensity pattern that reaches the workpiece after interaction with the powder jet. In the past, several statistical distributions have been proposed for modeling this intensity pattern. However, these require strong simplifications of the powder particle trajectories and do not take into account the complex powder flow profile that is present in practical systems. In this paper, the effect of the powder flow on the incident laser intensity is numerically studied under varying process conditions. A finite element simulation of the powder flow is performed and used to generate a set of powder particle trajectories using Monte Carlo simulation. A ray-tracing algorithm is developed to split the laser beam into multiple rays of light which get partly reflected and absorbed by the particles and the workpiece. Running the ray-tracing procedure over time allows the calculation of an averaged incident light intensity pattern as well as an averaged pattern of the energy absorbed by the particles that arrive at the workpiece. Several simulations are performed in order to study the effects of the used laser intensity pattern and the particle size distribution. The results are in good agreement with existing literature. V C 2015 Laser Institute of America. [http://dx

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Modeling of laser beam and powder flow interaction in laser cladding using ray-tracing

Devesse

Baere

Guillaume

2015

Journal of Laser Applications

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“…The additive material usually is in the form of metallic powder, which can be injected laterally or coaxially to the laser beam (Zekovic et al 2007). Between the two different ways of powder feeding, coaxial laser cladding is easier to realize automation because of its independence from the direction of motion (Pinkerton and Li 2004).…”

Section: Introductionmentioning

confidence: 99%

A Numerical Study on Metallic Powder Flow in Coaxial Laser Cladding

Líu

Hao

et al. 2016

JAFM

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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.

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“…Pinkerton and Li [16] constructed a model to describe the variation in powder stream concentration along the axis of a coaxial nozzle. It related directly to nozzle dimensions, material mass and volume flow rates, and was sufficiently simple not to rely on numerical techniques.…”

Section: Introductionmentioning

confidence: 99%

Solute transport and composition profile during direct metal deposition with coaxial powder injection

Song

et al. 2011

Applied Surface Science

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a b s t r a c tDirect metal deposition (DMD) with coaxial powder injection allows fabrication of three-dimensional geometry with rapidly solidified microstructure. During DMD, addition of powder leads to the interaction between laser and powder, and also the redistribution of solute. The concentration distribution of the alloying element is very important for mechanical properties of the deposited clad material. The evolution of concentration distribution of carbon and chromium in the molten pool is simulated using a selfconsistent three-dimensional model, based on the solution of the equations of mass, momentum, energy conservation and solute transport in the molten pool. The experimental and calculated molten pool geometry is compared for model validation purposes.

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Modelling Powder Concentration Distribution From a Coaxial Deposition Nozzle for Laser-Based Rapid Tooling

Cited by 126 publications

References 23 publications

Modeling of laser beam and powder flow interaction in laser cladding using ray-tracing

Modeling of laser beam and powder flow interaction in laser cladding using ray-tracing

A Numerical Study on Metallic Powder Flow in Coaxial Laser Cladding

Solute transport and composition profile during direct metal deposition with coaxial powder injection

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