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<p>Laser cladding is widely used for fabricating high-performance components due to its high energy density and strong interfacial bonding. However, unstable molten pool flow and microstructural defects limit process quality. ultrasonic-assisted laser cladding enhances cladding quality by introducing ultrasonic vibration to regulate molten pool dynamics. This study develops a two-dimensional multi-physics-coupled model incorporating the discrete phase model, k-omega shear stress transport turbulence model, and volume of fluid method to simulate molten pool behavior. User-defined functions integrate acoustic streaming and cavitation-related effects as momentum sources, systematically analyzing the influence of ultrasonic vibration. Results show that ultrasonic vibration significantly enhances convection, increasing the maximum flow velocity by 19% at a 24-μm amplitude and forming a more uniform dual-vortex structure. This stabilizes molten pool flow by mitigating surface tension–driven instabilities. Additionally, ultrasonic vibration improves the cladding layer’s geometry: height and width decrease by 20.5% and 10.3%, respectively, while the wetting angle is reduced from 51.2 to 42.6°, enhancing wettability and spreading. The effect of ultrasonic amplitude on flow and morphology exhibits nonlinear behavior, plateauing beyond 16&#xa0;μm. Although ultrasonic vibration introduces additional heat, its thermal contribution remains secondary compared to the laser heat input, while the peak temperature increases by approximately 200&#xa0;K, which may still influence the molten pool dynamics. This study elucidates the mechanisms by which ultrasonic vibration improves cladding quality through enhanced momentum transfer and heat conduction, providing theoretical insights for optimizing process parameters in ultrasonic-assisted laser cladding.</p>

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Numerical simulation of ultrasonic-assisted coaxial powder feeding laser cladding

  • 期刊论文

  • 发表日期：

    2026年5月21日

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  • Zaixin Wu,
  • Xiaopeng Liu,
  • Shixiao Li,
  • Wenkang Wang,
  • Dehong Guo,
  • Shixin Tang

摘要

Laser cladding is widely used for fabricating high-performance components due to its high energy density and strong interfacial bonding. However, unstable molten pool flow and microstructural defects limit process quality. ultrasonic-assisted laser cladding enhances cladding quality by introducing ultrasonic vibration to regulate molten pool dynamics. This study develops a two-dimensional multi-physics-coupled model incorporating the discrete phase model, k-omega shear stress transport turbulence model, and volume of fluid method to simulate molten pool behavior. User-defined functions integrate acoustic streaming and cavitation-related effects as momentum sources, systematically analyzing the influence of ultrasonic vibration. Results show that ultrasonic vibration significantly enhances convection, increasing the maximum flow velocity by 19% at a 24-μm amplitude and forming a more uniform dual-vortex structure. This stabilizes molten pool flow by mitigating surface tension–driven instabilities. Additionally, ultrasonic vibration improves the cladding layer’s geometry: height and width decrease by 20.5% and 10.3%, respectively, while the wetting angle is reduced from 51.2 to 42.6°, enhancing wettability and spreading. The effect of ultrasonic amplitude on flow and morphology exhibits nonlinear behavior, plateauing beyond 16 μm. Although ultrasonic vibration introduces additional heat, its thermal contribution remains secondary compared to the laser heat input, while the peak temperature increases by approximately 200 K, which may still influence the molten pool dynamics. This study elucidates the mechanisms by which ultrasonic vibration improves cladding quality through enhanced momentum transfer and heat conduction, providing theoretical insights for optimizing process parameters in ultrasonic-assisted laser cladding.