A 3-D transient finite element model for laser cladding by powder injection

Abstract

This paper presents a novel 3-D transient finite element model for laser cladding by a powder injection process. A solution strategy is proposed to predict clad geometry as a function of time and process parameters such as beam velocity, laser power, powder jet geometry, laser pulse shaping, and material properties. In the proposed method, the interaction between powder and melt pool are assumed to be decoupled and as a result, the melt pool boundary is first obtained in the absence of powder spray. Once the melt pool boundary is calculated, it is assumed that a layer of coating material based on powder feedrate and elapsed time is deposited on the melt pool in the absence of laser beam. The new melt pool boundary is then calculated by thermal analysis of the layer of deposited powder, substrate and laser heat flux. The results of numerical modeling are compared with experimental results. The comparisons show a good agreement between the modeling and experimental results.This paper presents a novel 3-D transient finite element model for laser cladding by a powder injection process. A solution strategy is proposed to predict clad geometry as a function of time and process parameters such as beam velocity, laser power, powder jet geometry, laser pulse shaping, and material properties. In the proposed method, the interaction between powder and melt pool are assumed to be decoupled and as a result, the melt pool boundary is first obtained in the absence of powder spray. Once the melt pool boundary is calculated, it is assumed that a layer of coating material based on powder feedrate and elapsed time is deposited on the melt pool in the absence of laser beam. The new melt pool boundary is then calculated by thermal analysis of the layer of deposited powder, substrate and laser heat flux. The results of numerical modeling are compared with experimental results. The comparisons sh...