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<p>With the development of laser additive manufacturing technology, the optimization of powder utilization rate has become an important factor affecting manufacturing efficiency and cost. In this paper, a continuous–discrete phase gas/solid coupling model of laser and powder interaction during laser cladding was established to calculate and reveal the temperature, concentration, and flow velocity distributions of powder under different process parameters. The effects of different process parameters on the powder convergence state and laser powder interaction were quantified. Multi-objective process parameter optimization is carried out by analyzing the influence of process parameters such as powder feeding pipe diameter, powder feeding angle, and gas feeding speed on the powder utilization rate in the molten pool. Combining the powder utilization rates under different process parameters, the optimal process parameters are obtained to maximize the powder utilization rate. On this basis, a multi-field coupling numerical model of the laser cladding process was established, and its transient evolution was revealed. The calculation shows that the powder temperature, concentration, flow velocity, and cladding layer height with a powder feeding pipe diameter of 1.64&#xa0;mm, a powder feeding angle of 65°, and a powder carrier gas velocity of 7.46&#xa0;m/s are more in line with the process requirements, and the convergence of the powder reaching the substrate is better.</p>

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Parameter Optimization of Fe60 Laser Cladding via a Gas/Solid Model for Enhanced Powder Flow

  • 期刊论文

  • 发表日期：

    2025年12月11日

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  • Weiwei Ge,
  • Chang Li,
  • Shuchao Li,
  • Fanhong Kong,
  • Xing Han

摘要

With the development of laser additive manufacturing technology, the optimization of powder utilization rate has become an important factor affecting manufacturing efficiency and cost. In this paper, a continuous–discrete phase gas/solid coupling model of laser and powder interaction during laser cladding was established to calculate and reveal the temperature, concentration, and flow velocity distributions of powder under different process parameters. The effects of different process parameters on the powder convergence state and laser powder interaction were quantified. Multi-objective process parameter optimization is carried out by analyzing the influence of process parameters such as powder feeding pipe diameter, powder feeding angle, and gas feeding speed on the powder utilization rate in the molten pool. Combining the powder utilization rates under different process parameters, the optimal process parameters are obtained to maximize the powder utilization rate. On this basis, a multi-field coupling numerical model of the laser cladding process was established, and its transient evolution was revealed. The calculation shows that the powder temperature, concentration, flow velocity, and cladding layer height with a powder feeding pipe diameter of 1.64 mm, a powder feeding angle of 65°, and a powder carrier gas velocity of 7.46 m/s are more in line with the process requirements, and the convergence of the powder reaching the substrate is better.