同轴激光熔覆粉末的熔化行为表征与分析

doi:10.7527/S1000-6893.2023.28581

Abstract

Abstract:

The action and distribution of laser heat in the powder and melt pool during coaxial powder feeding laser cladding has an important influence on the forming quality. This paper conducted research on the complex and challenging thermal interaction between powder and laser， particularly difficult to detect in real-time infrared analysis. Firstly， a high-speed camera system is established and the melting process of a single powder coaxially fed into the laser was collected and analyzed， and the thermophysical behavior of different characteristic stages of the powder melting process is studied and a mathematical model is established. Moreover， due to the difficulty in validating and optimizing the model based on valid temperature data， the duration of the different characteristic phases was statistically analyzed using high-speed cameras， and was compared with the calculated results of the model. Finally， based on the optimization of the model， the simulation predicted the temperature and state of the powder about to enter the melt pool， which provides a theoretical basis for further analysis of the thermal interaction between the powder and the melt pool. The results show that： there is a transition of “solid → solid-liquid two-phase state → liquid” after a single powder enters the melt pool， and the duration and thermophysical behavior of different transition processes are not the same； the mathematical model established by this can dynamically describe the duration and temperature characteristics of different melting stages after the powder is fed into the laser. The validity and accuracy of the model were verified by comparing with high-speed camera statistics. The simulation predicted the temperature characteristics of the powder when it was about to enter the melt pool， and analyzed the influence and effect of different laser powers on the state of the powder when it is about to enter the molten pool.

Key words: coaxial powder feeding, laser cladding, powder melting behavior, high-speed camera, molten pool

CLC Number:

V252

Ming ZHU, Zongzhi ZHANG, Qian YANG, Yu SHI, Ding FAN. Characterization and analysis of melting behavior of powder in coaxial laser cladding[J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(24): 428581-428581.

Figures/Tables 19

Fig.1

Table 1

Fig.2

Fig.3

Fig.4

Fig.5

Fig.6

Fig.7

Fig.8

Fig.9

Fig.10

Fig.11

Fig.12

Fig.13

Fig.14

Table 2

Fig.15

Fig.16

Fig.17

References 21

1	GU D D， MEINERS W， WISSENBACH K， et al. Laser additive manufacturing of metallic components： materials， processes and mechanisms［J］. International Materials Reviews， 2013， 57（3）：133-164.
2	张津超，石世宏，龚燕琪，等. 激光熔覆技术研究进展［J］. 表面技术， 2020， 49（10）： 1-11.
	ZHANG J C， SHI S H， GONG Y Q， et al. Research progress of laser cladding technology［J］. Surface Technology， 2020， 49（10）： 1-11 （in Chinese）.
3	杜学芸，许金宝，宋健. 激光熔覆再制造技术研究现状及发展趋势［J］. 金属加工（热加工）， 2020 （3）： 15-19.
	DU X Y， XU J B， SONG J. Research status and development trend of laser cladding remanufacturing technology ［J］. MW Metal Forming， 2020 （3）： 15-19 （in Chinese）.
4	周建忠，何文渊，徐家乐，等. 激光熔覆Al2O3/Fe901复合涂层的强化机制及耐磨性［J］. 光学学报， 2019， 39（5）： 219-227.
	ZHOU J Z， HE W Y， XU J L， et al. Strengthening mechanism and wear resistance of Al2O3/Fe901 composite coating prepared by laser cladding［J］. Acta Optica Sinica， 2019， 39（5）： 219-227 （in Chinese）.
5	白杨，王振华，左娟娟，等. 激光熔覆制备铁基复合涂层及其耐热耐蚀性能［J］. 中国激光， 2020， 47（10）： 38-44.
	BAI Y， WANG Z H， ZUO J J， et al. Fe-Based composite coating prepared by laser cladding and its heat and corrosion resistance［J］. Chinese Journal of Lasers， 2020， 47（10）： 38-44 （in Chinese）.
6	KATINAS C， THROOP T， SHIN YC， et al. Laser cladding of Stellite-6 with a coaxial nozzle via modeling and systematic experimental investigations［J］. The International Journal of Advanced Manufacturing Technology， 2021，113： 837–853.
7	ZHU S， CHEN W， DING L， et al. A mathematical model of laser cladding repair［J］. The International Journal of Advanced Manufacturing Technology， 2019，103： 3265-3278.
8	LI C， ZHANG D， YANG Y， et al. Research on sputtering behavior of three beams coaxial laser cladding powder based on the interaction of lasers and powder［J］. Journal of Laser Applications， 2021， 33（4）： 42020.
9	崔雪，张松，张春华，等. 高性能梯度功能材料激光增材制造研究现状及展望［J］. 材料工程， 2020， 48（9）： 13-23.
	CUI X， ZHANG S， ZHANG C H， et al. Research status and prospect of laser additive manufacturing technology for high performance gradient functional materials［J］. Journal of Materials Engineering， 2020， 48（9）： 13-23 （in Chinese）.
10	SHI B， LI T， GUO Z， et al. Selecting process parameters of crack-free Ni60A alloy coating prepared by coaxial laser cladding［J］. Optics and Laser Technology， 2022， 149： 107805.
11	HEIGEL J C， GOUGE M F， MICHALERIS P， et al. Selection of powder or wire feedstock material for the laser cladding of Inconel 625［J］. Journal of Materials Processing Technology， 2016， 231（12）： 357-365.
12	WIRTH F， WEGENER K. A physical modeling and predictive simulation of the laser cladding process［J］. Additive Manufacturing， 2018， 22： 307-319.
13	SCHOPPHOVEN T， GASSER A， WISSENBACH K， et al. Investigations on ultra-high-speed laser material deposition as alternative for hard chrome plating and thermal spraying［J］. Journal of Laser Applications，2016， 28（2）：022501.
14	IBARRA-MEDINA J， PINKERTON A J. Numerical investigation of powder heating in coaxial laser metal deposition［J］. Surface Engineering， 2013， 27（10）： 754-761.
15	TABERNERO I. Modelling of energy attenuation due to powder flow-laser beam interaction during laser cladding process［J］. Journal of Materials Processing Technology， 2012， 212（2）： 516-522.
16	GULYAEV I， KOVALEV O， PINAEV P A， et al. Optical diagnostics of radiation interaction with the powder stream laterally transported during laser cladding［J］. Optics and Lasers in Engineering， 2020， 126： 105877.
17	杨义成，黄瑞生，方乃文，等. 光粉交互对同轴送粉增材制造能量传输的影响［J］. 焊接学报， 2020， 41（6）： 19-23.
	YANG Y C， HUANG R S， FANG N W， et al. Effect of the interaction between laser beam and powder particles on energy transmission in coaxial powder feeding additive manufacturing［J］. Transactions of the China Welding Institution， 2020， 41（6）： 19-23 （in Chinese）.
18	TAN H， FANG Y， ZHONG C， et al. Investigation of heating behavior of laser beam on powder stream in directed energy deposition［J］. Surface and Coatings Technology， 2020， 397：126061.
19	朱明，王博，颜步云，等. 激光熔覆过程预置粉末熔化行为的动态检测与分析［J］. 中国激光， 2021， 48 （14）： 140201301-140201310.
	ZHU M， WANG B， YAN B Y， et al. Dynamic detection and analysis of fore put powder melting behavior in diode laser cladding process［J］. Chinese Journal of Lasers 2021， 48 （14）： 140201301-140201310 （in Chinese）.
20	ZHU M， YAN B Y， LI X B， et al. Process research on diode laser-TIG hybrid overlaying welding process［J］. Transactions on Intelligent Welding Manufacturing， 2019， 1：161-168.
21	席明哲，虞钢，张永忠，等. 同轴送粉激光成形中粉末与激光的相互作用［J］. 中国激光， 2005 （4）： 562-566.
	XI M Z， YU G， ZHANG Y Z， et al. Interaction of the laser beam and the metal powder conveyed by coaxial powder feeder［J］. Chinese Journal of Lasers， 2005 （4）： 562-566 （in Chinese）.

参数	数值	参数	数值
激光功率（P）	100~1 500 W	玻尔兹曼常数（σ）	5.67×10^-14 W/（mm²·℃⁴）
离焦量（D）	0~+15 mm	熔化潜热（Q_p-latent）	30.375 J/g
粉末粒径（r_p）	120 µm	固态粉末吸收率（α_solid）	0.75
粉末初速度（v₀）	0.6~1.2 mm/ms	液态粉末吸收率（α_liquid）	0.4
粉末入射角度（θ）	20°~45°	固态粉末对流热换系数（h_p-solid）	6×10^-6 W/（mm²·℃）
送粉高度（d）	10~25 mm	液态粉末对流热换系数（h_p-liquid）	1.2×10^-5 W/（mm²·℃）
发射系数（ε）	0.345 2	固态粉末比热（C_p-solid）	0.457 1 J/（g·℃）
环境温度（T₀）	25 ℃	液态粉末比热（C_p-liquid）	0.535 J/（g·℃）
粉末熔点（T_m）	1 060 ℃	固态粉末密度（ρ_p-solid）	8.32×10^-3 g/mm³
粉末沸点（T_b）	2 700 ℃	液态粉末密度（ρ_p-liquid）	8.212×10^-3 g/mm³

[1]	Zhiqiang ZHANG, Ziming YU, Tiangang ZHANG, Qian YANG, Hao WANG. Microstructure of TiC _x reinforced Ti-based composite coating prepared by laser cladding and first principle study on reinforced phase [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2023, 44(8): 427294-427294.
[2]	DUAN Yucong, WANG Xuede, ZHOU Xin, ZHANG Peiyu, GUO Xiyang, CHENG Xing, FAN Junwei. Machine learning of emission intensity signal of laser powder bed fusion molten pool [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(9): 425855-425855.
[3]	CHEN Bo, MENG Zheng, MA Chengyuan, XI Xin, WANG Xinxin, TAN Caiwang, SONG Xiaoguo. Welding properties and molten pool flow behavior of TC4 titanium alloy by oscillating galvanometer laser [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(4): 525223-525223.
[4]	QU Ruizhi, HUANG Liangpei, XIAO Dongming. Numerical simulation of melt pool evolution and metal spattering characterization during selective laser melting processing [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(4): 525240-525240.
[5]	YONG Yaowei, ZHAO Ruiheng, WANG Jun, ZHANG Shuai. Properties of nickel-based composite alloy coating on copper reinforced by laser cladding [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(4): 525604-525604.
[6]	ZHANG Zhiqiang, YANG Fan, ZHANG Hongwei, ZHANG Tiangang. Microstructure and wear resistance of TiC_x reinforced Ti-based laser cladding coating with rare earth [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2021, 42(7): 624115-624115.
[7]	ZHANG Tiangang, ZHANG Qian, ZHUANG Huaifeng, LI Baoxuan, XU Yutong. Microstructure and properties of TiC-TiB₂ composite phase Ti-based rare earth laser cladding layers [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2021, 42(7): 424139-424139.
[8]	ZHANG Tiangang, ZHUANG Huaifeng, XUE Peng, ZHANG Qian, YAO Bo, LI Baoxuan. Microstructure refinement mechanism and properties of Ti-based rare earth laser cladding layers [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2020, 41(9): 423553-423553.
[9]	WANG Xiaoming, ZHU Sheng, YANG Baijun, ZHANG Yao, XU Anyang. Aluminum-based metallic glass coatings prepared with magnetic field assisted laser cladding [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2018, 39(11): 422134-422142.
[10]	LIU Jun, LI Yulong, GUO Weiguo, SHI Xiaopeng, PENG Gang, YE Biao. Parameters Inversion on Bird Constitutive Model PartⅠ: Study on Experiment of Bird Striking on Plate [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2011, 32(5): 802-811.
[11]	Guo Zhide. AN EXPERIMENTAL STUDY OF STRENGTHENING TECHNOLOGY BY LASER CLADDING [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 1995, 16(2): 82-84.

Characterization and analysis of melting behavior of powder in coaxial laser cladding

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 19

References 21

Related Articles 11

Recommended Articles

Metrics

Comments