Additive manufacturing has gained prominence in recent times. Laser powder feed additive manufacturing (LPF-AM) is a method to deposit materials layer by layer sequentially. The laser power attenuation is pivotal in determining the quantity of power that ultimately arrives at the surface during laser cladding. Investigating the laser power attenuation necessitates an in-depth analysis of the intricate interplay involving the laser beam and the powder. In the present work, the laser intensity and powder particle distribution are analyzed analytically. The amount of loss of power for three-jet powder feed (PF) nozzles while interacting with the laser beam is estimated. Mathematical tools are employed to solve the pertinent equations, simulate the process, and determine the distribution of particles, laser intensity distribution, and the relationship between the laser beam and powder. The simulations provide the dependence of power attenuation by the LPF-AM on the varying power size, carrier gas flow rate, and powder flow rate. The simulation results provide more profound insights into the interaction among the laser beam and powder particles at the consolidated plane below the nozzle, where the powder is deposited on the work surfaces. The findings from current research work will be helpful in estimating the absorbed energy by the powder particles and also the rise in powder temperature before depositing on the substrate surface.

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A Numerical Simulation of Ceramic Powder Particles Interaction with Laser Powder Feed Additive Manufacturing

  • Amit Kumar,
  • G. L. Samuel

摘要

Additive manufacturing has gained prominence in recent times. Laser powder feed additive manufacturing (LPF-AM) is a method to deposit materials layer by layer sequentially. The laser power attenuation is pivotal in determining the quantity of power that ultimately arrives at the surface during laser cladding. Investigating the laser power attenuation necessitates an in-depth analysis of the intricate interplay involving the laser beam and the powder. In the present work, the laser intensity and powder particle distribution are analyzed analytically. The amount of loss of power for three-jet powder feed (PF) nozzles while interacting with the laser beam is estimated. Mathematical tools are employed to solve the pertinent equations, simulate the process, and determine the distribution of particles, laser intensity distribution, and the relationship between the laser beam and powder. The simulations provide the dependence of power attenuation by the LPF-AM on the varying power size, carrier gas flow rate, and powder flow rate. The simulation results provide more profound insights into the interaction among the laser beam and powder particles at the consolidated plane below the nozzle, where the powder is deposited on the work surfaces. The findings from current research work will be helpful in estimating the absorbed energy by the powder particles and also the rise in powder temperature before depositing on the substrate surface.