Numerical simulation of metallic powder flow in a coaxial nozzle in laser direct metal deposition

To investigate the influencing rule of deposited layer’s shape on coaxial powder feeding flow field in the metal forming process, gas–solid two-phase flow theory is used to analyze effect of deposited layers on powder concentration distribution and variation of focus distance from nozzle outlet to convergence point (the center of the convergent zone). Different height and width parameters of deposited layers were chosen to calculate the powder concentration distribution, consequently, and also their effect on additive height of single-trace cladding layer was studied by experimental investigations. The numerical results are in good agreement with experimental observations. The results indicated that additive height of cladding layer was non-uniform under uneven wall thickness of parts fabrication condition. Consequently, the surface of deposited layers with uneven thickness is not smooth, and hence affects surface forming quality.     

Numerical studies on velocity, temperature history and heat transfer to the particles injected into the argon plasma

A new approach to study the particle velocity in a thermal plasma in relation to input parameters (power, gas flow rate, injection velocity of the particle and particle size) and nozzle dimensions (nozzle length and diameter) has been made. Injected particle's temperature and thermal history were calculated for particles of three different materials (alumina, tungsten and graphite) in argon plasma. Allowable powder feed rate was calculated for the particles. Heat transfer per particle injected in to the plasma is reported. Liquid fraction of the particle after it reached the melting point is also reported. Particle velocity is found to increase with increase in power, gas flow rate and injection velocity and decrease with increase in particle size, nozzle length and nozzle diameter. Thermal histories of the particles in relation to the plasma temperature and particle diameter are presented. Particle's residence time is found to increase with increase in diameter of the particle. Allowable powder feed rate for complete melting of the particle is higher at higher percentage utilisation of the plasma power. Powder feed rate is seen to decrease with increase in particle size and it is higher for tungsten and lower for graphite particle. Heat transfer rate from plasma to particle is seen to decrease with increase in time and the same is higher for plasmas of higher temperature and smaller sized particle. Received 4 May 2000 and Received in final form 15 March 2001     

激光熔覆中金属粉末粒子与激光相互作用模型

为了对同轴激光熔覆过程中运动的金属粉末粒子的速度和温度进行理论分析,并研究各工艺参量的影响,建立了运动中金属粉末粒子的运动模型和热模型.模拟结果表明,粉嘴几何尺寸、粒子直径以及气/粉两相流初始速度是影响粒子运动行为的重要因素;粉嘴几何尺寸、激光焦点位置、激光发散角、激光功率、粒子直径以及气/粉两相流初始速度是影响粒子热行为的重要因素.在相同的工艺参量下(粉嘴出口内径r=2 mm,粉嘴倾角α=60°,初始气流速度v0=0.8 m/s),基于数字粒子图像测速(DPIV)技术,对316L不锈钢粉末粒子运动模型进行了实验验证.结果表明,运动理论模型是可靠的.该模型是掌握同轴激光熔覆过程中金属粉末粒子运动行为的有效工具;同时,热模型也是分析粉末粒子温度随不同参量变化的重要工具.     

出口雷诺数对平面射流自保持性的影响

通过实验研究出口雷诺数对平面湍流射流自保持性的影响. 测量的射流来自相同的喷嘴但不同的雷诺数Re（≡U_jh/ν,其中U_j是出口平均速度、h是窄缝出口的厚度和ν是黏性系数）,其变化范围是Re=4582—57735.所得的数据包括沿轴线的平均速度、湍流强度、积分尺度、高阶矩和能谱. 实验发现,随着Re的增大,平面射流发展减慢,平均速度和湍流强 关键词： 平面射流 雷诺数 自保持性     

Experimental Investigation Of Spray Cooling Heat Transfer On Straight Fin Surface Under Acceleration Conditions

A spray cooling heat transfer experiment on straight fin surface under acceleration conditions was conducted to investigate the effects of acceleration, flow rate, and nozzle height. The results show that the acceleration can improve the heat transfer performance in a limited way. In addition, whether in the acceleration or stationary condition, the flow rate as well as the nozzle height has the same impact on the spray cooling performance. It is also observed that the surface temperature can influence the effect of flow rate on spray cooling performance, and the cooling performance becomes worse with the increase of nozzle height.     

An experimental study of the natural noise in the Transit-M hypersonic wind tunnel

Tests were performed at Mach number M = 6. Observations of flow pulsations were performed with the help of high-frequency measurements of pressure and heat fluxes and with the help of hot-wire anemometry. Measurements were carried out in a broad range of Re₁ numbers at various orientations and locations of sensors with respect to the nozzle exit plane. It is shown that the Transit-M noise varies weakly over the longitudinal coordinate, whereas on moving along the radial coordinate, some increase of the fluctuation level is observed due to approaching the mixing layer. Also, the distribution of axial asymmetry of the noise level was obtained.     

Active control of coaxial jet mixing with manipulation of primary vortical structures by arrayed micro flap actuators

Active mixing control of a methane/air isothermal coaxial jet was achieved using micro magnetic flap actuators arranged on the inner surface of the outer annular nozzle. The spatio-temporal evolution of vortical structures and the scalar mixing were studied through the particle image velocimetry and planar laser-induced fluorescence methods. In contrast to studies on jet control using acoustic forcing, the mechanical movement of the flap directly generated large-scale intense vortices. The mixing was enhanced significantly by the vortices formed in the inner shear layer, although the control input was given to the outer shear layer. It was found that the primary vortex rings dominated the near-field mixing, while streamwise vortices were responsible for the downstream mixing. It was also demonstrated that the radial range of the inner fuel transportation could be manipulated flexibly by adjusting the shedding interval of the vortices. Especially, the mixing was enhanced most significantly when the primary vortices were most densely populated near the nozzle exit at the control Strouhal number of unity.     

Flow characteristics of an offset jet over a surface mounted square rib

A three-dimensional offset jet flow over a surface mounted square rib was investigated using particle image velocimetry at Reynolds number of 7600. The square rib was mounted at three different locations downstream of the nozzle exit. Contour and profile plots in the symmetry plane were used to investigate the effect of the rib on the mean flow distribution and turbulence statistics. Changing the rib location enhanced the mixing and entrainment characteristics of the jet thereby leading to larger wall-normal spread rates. The quadrant analysis revealed a significant contribution of all events towards the Reynolds shear stress. The joint probability density function analysis showed that the structures within the outer shear layer of the jet differed from those of boundary layers. Results from the two-point correlation analysis indicated that the introduction of a surface mounted rib modified the flow structures within the developing region. However, there was no significant structural difference between the flow with mounted rib and the no rib case within the self-similar region. The proper orthogonal decomposition was used to examine how changes in rib location modified the dynamics of the energetic modes towards the turbulent kinetic energy and Reynolds shear stress within the developing and self-similar regions.     

Influences of different powders on the characteristics of particle charging and deposition in powder coating processes

This experimental study investigated the influences of two different powder systems (coarse and ultrafine) on particle charging and deposition characteristics during electrostatic powder coating processes. Results disclosed that, despite their differences in particle sizes, the two powders behave similarly in deposition process, commonly resulting in a cone-shaped deposited pattern in the inner portion of the substrate and an increase of deposited particles in the fringe region. However, their different properties lead to the discrepancies in their deposition efficiencies, which account for a higher efficiency with the coarse powder. The study further revealed that the coarse powder is superior to the ultrafine powder in charging in-flight particles, which directly contributes to its higher deposition efficiencies. Furthermore, it was disclosed that the two powders exhibit distinct characteristics in charging deposited particles. Compared to the coarse powder, the ultrafine powder is more uniform in charging deposited particles, mainly owing to its greater particle number and higher specific surface area but less mass. In particular, the charging efficiency of overall deposited particles decreases for the ultrafine powder but increases for the coarse powder with increased charging voltage, closely related to their particle properties. However, both powders decrease in charging efficiency of deposited particles with extended spraying duration due to back corona intensifying with spraying.     

平面射流沿轴线的特征尺度及其对测量信号过滤程度的依赖

对出口雷诺数约为13000的湍流平面射流瞬时速度(u)测量信号(u_m)进行高频过滤研究. 在分析了高频噪声对u测量精度的影响后,使用Mi等人 (2005, Phys. Rev. E 71, 066304)提出的快速收敛迭代法对u_m进行了数值过滤,并考察过滤前后统计湍流量的变化. 结果发现,噪声的存在不仅对湍流小尺度统计量的估算影响显著,也对与大尺度关联的量产生一定的影响. 在有效去除噪声造     

Estimation of water-surface deformation by vortices in a viscous horizontally decelerating air flow

The maximum height of a disturbance on the water surface, which occurs when a spatial (non-point) vortex departs from a viscous layer of a horizontal air flow that decelerates in the direction of motion, is estimated. The dependence of the initial disturbance parameters on the air flow speed over the water surface is derived. It is shown that the height of the disturbance increases and its width decreases with an increase in the air flow speed. The suggested model is verified experimentally.     

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.     

冲击射流激波振荡与抑制

欠膨胀冲击射流具有复杂的激波结构,并伴随产生高幅值的离散频率单音.通过高速摄像获取的纹影图像并结合噪声测量,对欠膨胀冲击射流激波振荡过程、剪切层不稳定波的模态和离散频率单音的产生进行了系列研究.给出了冲击距离为5倍喷嘴出口直径的复杂流动实验结果分析,射流剪切层不稳定波有对称和非对称两种模态,发现不同模态下的离散频率单音...     

Analysis and prediction of single laser tracks geometrical characteristics in coaxial laser cladding process

Direct Laser Fabrication is a promising new manufacturing technology coming from laser cladding process. From a coaxial nozzle, powder is fed through a laser beam on a substrate. The powder melting and solidification processes lead to the fabrication of a part layer by layer. In this work 316L stainless steel powder is used to form laser tracks on a low carbon steel substrate. The layer geometry is an important process characteristic to control the final part of fabrication. This paper presents analytical relationships between the laser tracks geometrical characteristics (width, height, area, penetration depth) and the processing parameters (laser power P, scanning speed V and powder mass flow Q_m). Three values of each processing parameters are fixed and so 27 different experiments have been made and analyzed. The validity of these results is discussed studying the correlation coefficient R, the graphical analysis of the residuals and the uncertainty evaluations. Two kinds of models are studied to predict the form and the geometrical characteristics of the single laser tracks cross sections. The first one is an analytical model in which the distribution of the powder in the feed jet is supposed to govern the laser clad geometry. Three distributions are proposed: Gaussian, uniform and polynomial. In the second model the general form of the clad cross section is supposed to be a disk due to the surface tension forces. Analytical relationships are established between the radius and the center of the disk in one hand and the process parameters in the other hand. This way we show that we can reproduce the laser track geometry in all the area experimentally explored.     

矩形喷口欠膨胀超声速射流对撞的实验研究

在不同喷口间距和射流压力下开展了矩形喷口欠膨胀超声速射流对撞实验并与自由射流进行了对比. 实验表明:超声速射流对撞的辐射噪声中存在四种不同的啸音模式, 且随喷口距离和射流压力的变化在不同模式间切换. 在射流压力大于0.5 MPa且喷口间距小于50 mm时, 射流对撞面在两个喷口外形成两道正激波之间, 啸音基频维持在3 kHz左右. 随喷口间距的增大或射流压力的降低, 射流对撞面在一侧喷口外的弓形激波与另一侧喷口外的正激波之间. 对撞面也有可能出现在两个弓形激波之间, 对应的啸音基频约为9 kHz, 但容易受扰动而回到喷口一侧或是在喷口之间大幅度振荡. 当射流压力小于0.36 MPa且喷口间距大于70 mm后, 对撞面在两个喷口之间大幅度振荡, 产生基频在1 kHz左右并随射流压力的降低和喷口间距的增大而降低的啸音. 关键词： 超声速射流 啸音 射流对撞 激波     

保护气对切割弧特性影响的模拟研究

通过比较两种不同结构切割炬所产生的等离子体流场,发现保护气对等离子体的温度和速度分布影响很小.垂直保护气在切割炬喷口形成阻碍作用,造成切割炬内的压强有所升高,但是增加不大.两种结构保护气对切割弧的影响只是在炬喷口外的激波附近.加入保护气后激波的强度会减弱.相对于没有保护气的情况,保护气增加冷却作用,弧电压会略有升高.当改变保护气的成分时,发现弧柱区的氧气含量不受影响,所以保护气成分的改变不会影响到弧电压.计算发现轴线处氧气和周围气体的混合很少,在喷口下游10mm处,氧气的摩尔分数仍在90%以上. 关键词： 等离子体切割弧 保护气 数值模拟     

强梯度复杂流场中的粒子动力学响应试验研究

示踪粒子在(高)超声速流场中的动力学响应是粒子成像测速等粒子示踪测量技术的关键问题之一.现有文献对粒子动力学响应的试验测量往往是通过单个斜激波响应的测量方法.然而,当示踪粒子用于测量高速飞行器发动机内部复杂的激波串流场时,粒子将经历由多道激波导致的速度、压力、黏性等剧烈变化.本文结合目前(高)超声速飞行器的研究热潮,重点关注示踪粒子在应用于发动机内部具有连续激波的复杂流场测量中存在的跟随性评估方面,开展了一系列的相关试验研究.包括测量超声速风洞的喷管出口速度分布以验证测试系统的性能,在马赫4.2和3.0流场中测量了粒子对二维10°和15°单斜劈绕流中的斜激波动力响应,并测量了模拟发动机内部连续梯度的双斜劈粒子斜激波动力响应.结合粒子动力学的理论模型,得到了各状态的粒子弛豫时间、弛豫距离、Stokes数.基于图像方法、统计学规律分析了激波非定常抖动对测量结果的影响,并对测量结果进行了修正.结果显示,相同斜劈角度下,马赫数越高,粒子的弛豫时间、弛豫距离就越大.但是在相同的来流马赫数下,斜劈角度越大,粒子的弛豫时间、弛豫距离反而减小.在强梯度之后由于流场的雷诺数和黏性系数变化剧烈,粒子的跟随性降低了大约5.7%,stokes数增加了约1%.虽然在本文条件下Stokes数仍满足超声速流场对粒子跟随性的要求,但粒子响应的降低无疑是值得关注的,尤其是当其被应用于具有更多连续梯度的复杂流场测量中.     

氮气稀释下丙烷层流扩散火焰的抬升特性研究

本文实验研究了氮气稀释条件下,丙烷层流扩散火焰的抬升特性。主要研究了混合物组分及射流出口速度对丙烷抬升火焰抬升高度的影响,得到了氮气稀释下丙烷抬升火焰的再附着滞后现象,并采用计算方法得出了理论火焰抬升高度,与实验数据进行了对比分析,二者符合很好。     

SERS activity of gas-evaporated silver particles

We have produced silver particles by the gas-evaporation technique and investigated their SERS activity. The enhancement factor is determined quantitatively by measuring the Raman intensity of copper phthalocyanine molecules deposited onto the particle layer. It is shown that the particle layer is a good SERS enhancer, which yields an enhancement of ～ 4 × 10³. It is also shown that a five-fold increase in the enhancement factor is obtained, when the particle layer is coated with a 30 nm silver film. The enhancement presently observed seems to arise from the electromagnetic effects, namely, the excitation of localized surface plasmons for the bare particle layer and that of extended surface plasmons for the silver-coated particle layer.