Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts

Abstract

Since shaft parts operate under harsh environments for a long time, many critical parts suffer from corrosion, wear and other problems, leading to part failure and inability to continue in service. It is imperative to repair failed parts and increase their service life. An orthogonal experimental scheme is designed to numerically simulate the process of laser cladding of Inconel 718 alloy powder on 4140 alloy structural steel based on the ANSYS simulation platform, derive the relationship equation of cladding layer thickness according to the heat balance principle, establish a finite element model, couple three modules of temperature field, stress field and fluid field, and analyze different modules to realize the monitoring of different processes of laser cladding. The optimal cladding parameters were laser power 1000 W, scanning speed 15 rad/s, spot radius 1.5 mm, thermal stress maximum value of 696 Mpa, residual stress minimum value of 281 Mpa, and the degree of influence of three factors on thermal stress maximum value: laser power > spot radius > scanning speed. The pool in the melting process appears to melt the “sharp corner” phenomenon, the internal shows a double vortex effect, with a maximum flow rate of 0.02 m/s. The solidification process shows a different shape at each stage due to the different driving forces. In this paper, multi-field-coupled numerical simulations of the laser cladding process were performed to obtain optimal cladding parameters with low residual stresses in the clad layer. The melt pool grows and expands gradually during melting, but the laser loading time is limited, and the size and shape of the melt pool are eventually fixed, and there is a vortex flowing from the center to both sides of the cross-section inside the melt pool, forming a double vortex effect. The solidification is divided into four stages to complete the transformation of the liquid phase of the melt pool to the solid phase, and the cladding layer is formed. The multi-field-coupled numerical simulation technique is used to analyze the temperature, stress and fluid fields to provide a theoretical basis for the residual stress and surface quality of the clad layer for subsequent laser cladding experiments.

Single-channel multilayer forming mechanism of laser cladding Fe60 process under different laser heat source working mode

“…Nevertheless, the molten pool is not in a stationary condition. The flow of the molten pool is mainly controlled by the Marangoni flow, the gravitational force inside and the solidification phase change, among which the gravitational force and the solidification phase change are inherent properties of the material [32]. The Marangoni flow is controlled by the temperature gradient, and the alloying elements as well as the fluid in the molten pool are actually in a real-time flow state.…”

Study on the reduction of residual stress in laser cladding layers through groove texture

“…The multi-field coupling numerical simulation technique is an advanced method of coupling different physical fields for the purpose of conducting simulation analysis 28 . Through multi-field coupling numerical simulation, it is possible to more accurately simulate real-world scenarios, including the interactions between different physical fields, thereby improving the accuracy and reliability of the simulation results.…”

Microstructure and Wear Resistance of Ti5Si3/Ti3Al Composite Coatings Prepared by Laser Cladding on TA2 Titanium Alloy

“…Moreover, in the process of laser cladding, in addition to the influence of laser cladding process parameters on the temperature field and velocity field of the molten pool, the surface tension coefficient of the material also has an impact on the temperature and velocity field of the molten pool [43]. When the surface tension coefficient of the material is less than 0, the melt in the molten pool flows from the laser center to the edge of the molten pool.…”