Abstract
The powder distribution and interaction between the laser beam and powder flow affect the deposition quality during the process of laser direct energy deposition with a continuous coaxial nozzle. In this paper, some key analytical formulae related to the laser beam-powder flow interaction are comprehensively deduced and validated. The powder distribution formulae for different regions are first established considering the divergence angles of powder jet. The energy attenuation formulae of laser beam passing through the powder flow are derived considering the change of powder distribution from annular to circular Gaussian modes. The temperature formulae of powder particles passing through the laser beam are derived based on a proposed temperature formula with the solid-liquid phase transition, and the powder temperature is also further analyzed. These formulae are validated by published deposition examples and used to analyze the laser beam-powder flow interaction.
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