激光熔覆中同轴粉末流温度场的数值模拟

在激光同轴送粉熔覆中,由于激光与粉末流相互作用,粉末流整体温度分布直接影响激光熔覆的质量.基于非预混燃烧模型,将激光相处理为连续性介质,粉末颗粒相看作离散相物质,建立了激光作用下粉末流的质量、动量和能量方程.用Fluent软件进行了不同激光功率和粉末流速度条件下粉末流整体温度场数值模拟,讨论了各种参数对温度场分布的影响.为了验证该模型的准确度,利用CCD比色测温方法测量了粉末流整体温度场分布.结果表明,数值模拟与CCD检测结果具有良好的一致性,数值模拟结果对激光熔覆具有指导意义.     

激光熔覆中球形粒子对激光散射强度的研究

为了研究同轴激光熔覆过程中球形粉末粒子和激光的相互作用,为激光熔覆中激光器和粒子的选择提供一定的理论依据,在进行了一定假设的前提下,应用米氏(Mie)散射理论建立了激光被球形粉末粒子散射的物理模型,应用Mathematica数学软件绘制出了在不同粒子半径和不同激光波长情况下,激光被球形粉末粒子散射后的强度分布图,并对模拟结果进行了分析.研究结果显示:金属粉末粒子的半径和激光的波长是影响激光散射强度分布的重要因素.结果表明:当光学常数q≤30的时候,散射光强在偏离传播方向20.以外还有一个次极大值,且次极大值占总散射光强比例较大,不利于熔池的形成;当光学常数q≥30的时候,散射后的光强主要集中在偏离传播方向5.～6.的小范围内,且在此范围内的散射强度很高,有利于提高激光熔覆效率.     

激光熔覆中同轴送粉气体-粉末流数值模拟

应用FLUENT软件的离散相模块建立了激光熔覆中气体 粉末流的二维模型,研究了保护气和输送气流量及送粉量对粉末流浓度场和速度场的分布规律的影响以及对粉末流发散角和焦点的影响。计算结果表明:随着输送气流量的增大,粉末流速度增加,粉末流发散角逐渐减小;送粉量增加,焦点略微下移,焦点处粉末流浓度值增大。在相同的工艺参数下,使用单反相机拍摄粉末流分布,结果表明试验与计算结果基本吻合。     

激光工业应用

使用2 kw半导体激光在工具钢表面熔覆高速钢粉末。在同轴送粉的粉末汇聚点与激光的聚焦点可获得无裂纹的熔覆层。随着激光功率的增加,熔覆层厚度和粉末利用率增加,同时基体对熔覆层的稀释率下降。获得的熔覆层的硬度达到800 Hvo.3,基体硬度200 Hvo.:,表明     

基于能量法的激光熔覆构件疲劳寿命评估研究北大核心CSCD

激光熔覆零件疲劳寿命评估一直是制约激光熔覆技术在工程中推广应用的一个重要因素,现有研究多为试验研究,缺乏理论分析。为量化评估激光熔覆试件的疲劳寿命,并确定熔覆过程的最优速度参数,采用能量法,综合考虑相变及熔覆过程能量变化规律,建立了激光熔覆构件疲劳寿命评估模型,模型计算结果和试验结果基本吻合。评估模型计算结果表明采用同步送粉法,激光功率、光斑直径及送粉速率一定的情况下,V是180mm/min时为最优参数。     

镍基合金激光熔覆数值模拟及凝固参数预测

本文采用有限体积法对激光熔覆过程的温度场分布和熔体流动进行了数值模拟.基于CALPHAD相图法计算了基体和粉末的热物理性质,采用三维热源精确预测了凝固过程和温度分布,研究了Marangoni对流对熔池尺寸的影响.在熔池凝固过程中模拟所得出的温度梯度和凝固速度,预测了熔覆层凝固组织的演变趋势,相应的显微组织与实验结果吻合...     

激光熔覆硬质合金强化化纤切断刀的研究

在机械压制法预置硬质合金WC/Co粉末的条形55Si2Mn弹簧钢上,用激光熔覆方法制备了化纤切断刀.调整熔覆层粉末配方中Al、TiC的加入量,结果表明加适量的Al粉能有效地抑制气孔,加TiC粉末能提高熔覆硬度.通过优化激光熔覆工艺参数,得到了无气孔缺陷、组织性能良好、硬度达到HV0.21250的激光熔覆层,达到了化纤切断刀的性能要求.     

送粉角度对激光熔覆铁基复合涂层形状特征的影响

通过分析激光熔覆过程中光束、粉末和熔池间的作用机理,建立了送粉式激光熔覆材料有效利用率的数学模型,在此基础上推导了送粉角度与工艺参数之间的定量关系式,并计算了不同送粉角度下的熔覆材料有效利用率、熔高和横截面积。结果表明,在熔覆工艺参数不变的条件下,理论计算的熔覆材料有效利用率、熔覆层高度和横截面积均随送粉角度的增加而增大,且均高于实验检测值。激光熔覆过程中,由于粉末烧损和机械损失,使熔覆材料有效利用率、熔高和横截面积随送粉角度变化出现最大值,理想送粉角度为60。     

用脉冲激光同轴全息技术测量微射流

强冲击载荷下自由表面的粒子喷射现象还没有被清楚认识，很难从理论上给以准确的计算模型，因而从实验测定材料在冲击载荷下自由面面喷射物质的分布和粒子尺寸大小就显得非常重要。测量微粒场的脉冲激光同轴全息技术，具有在纳秒或更在短时间内“固化”运动微粒场、测量精度高、景深长、光路简单和获得的信息量大等优点。这些优势使得脉冲激光同轴全息技术成为研究微喷射场的重要测试手段之一。     

脉冲Nd:YAG激光熔覆修复塑料模具工艺参数的优化

 激光器的电压、电流、脉冲宽度、脉冲频率与激光的扫描速度、光斑直径等工艺参数直接影响着脉冲Nd:YAG激光熔覆质量。为了简化工艺调整过程，提出了重叠率的概念，并进行了理论推导，建立了重叠率与脉冲频率、激光扫描速度、激光光斑直径相互关系的方程式。利用预置法在低碳钢基体上熔覆Ni基合金粉末,获得了2组最佳工艺参数，即单脉冲能量、重叠率分别为6.7 J,97.4%和21 J,69.4%。研究表明：在单脉冲能量和重叠率一定的条件下，改变电流、脉宽、脉冲频率及熔覆速度不会影响熔覆质量。     

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.     

Temperature analysis of the powder streams in coaxial laser cladding

The powder stream temperature of a newly developed coaxial laser cladding technique have been calculated and measured in this study. A simplified one-dimensional model of the particle heating problem under laser irradiation was solved with various conditions of laser intensity, particle size and flow velocity. The experimental results have been successfully detected by a pin-hole infrared sensor with the temperature calibration for hot particles. The thermal profiles of the coaxial nozzle give an optimum operation range of the stand-off distance for coaxial laser cladding.     

Velocity Distribution of the Powder Particles in Laser Cladding

The velocity distribution of powder particles in the laser cladding has an important influence on the motion of liquid in the laser molten pool. In this paper, considering the carrier gas leaving the nozzle to be a steady jet, the velocity distribution of the powder particles is obtained, which can be used as input data in the modelling of the laser cladding.     

Velocity Distribution of the Powder Particles in Laser Cladding

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Concentration model based on movement model of powder flow in coaxial laser cladding

The structure below the coaxial nozzle is critical since the spatial distribution of metal powder particles determines the laser attenuation as well as catchment efficiency. It is difficult to simulate the powder concentration distribution, because the complex phenomena involved in the two-phase turbulence flow. In this paper, the air-powder flow is studied along with powder properties, nozzle geometries and shielding gas setting. A Gaussian model is established to quantitatively predict the powder stream concentration in order to facilitate coaxial nozzle design optimizations. An experimental setup is design to measure the powder concentration for this process. The simulated results are compared with the experimental results. This study shows that the powder concentration mode is influenced significantly by powder properties, nozzle geometries and shielding gas setting.     

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.     

Thermal processes of a powder particle in coaxial laser cladding

This paper presents a numerical analysis of the heating, melting and evaporation processes of a single spherical powder particle when irradiated by a CO₂ laser beam in coaxial laser cladding. The power particle has a size ranging from 20 to 200 μm and the intensity of the laser has been varied from 500 to 3000 W. The laser energy, initial powder velocity and size have been shown to have important effects on the temperature profile of the powder stream. It has also been shown that high powder evaporation due to high power laser radiation may induce significant loss in the powder particle mass, to as much as 25% of the initial size at certain conditions in the simulation.     

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     

Laser scattering by metallic particles in two-phase nozzle flow into a vacuum

For several years the Max-Planck-Institute for Extraterrestrial Physics has performed experiments with artificial barium clouds in space by means of research rockets and satellites in order to investigate electric fields and currents in the ionosphere and in the magnetosphere. The processes which lead to the formation of these artificial clouds were simulated in laboratory in order to optimize the barium vapor yield and to obtain a better insight into the initial phase of the clouds. In these experiments the combustion of excess barium with copper oxide, the two-phase flow of the combustion products through a nozzle and their expansion into a 20 m³ vacuum chamber were investigated in detail. Purpose of this work is to measure through detection techniques of scattered laser light and thermal radiation: 1) the density of small metall particles on the particle jet axis, 2) the particle velocity, 3) the thermal radiation of larger particles, and 4) the position of the Mach disk which limits the free nozzle jet downstream. This work was carried out at the Max-Planck-Institut für extraterrestrische Physik, Garching, Germany.