Abstract
Coaxial powder feeding technology in the field of metal additive manufacturing is booming. In this paper, a new laser cladding nozzle with powder feeding channels of inner and outer rings is designed. The nozzle works with a new kind of laser, which is a new heat source with an inner beam and outer beams. The water-cooling channels are simulated in Ansys Workbench. The simulation results present the temperature distribution of the working nozzle and the velocity of the cooling water. The thermal dilation of the nozzle in the working environment is also simulated. The results show that the loop water cooling channel could effectively reduce the high temperature of the nozzle down to about 200 °C. In addition, it could well restrain the thermal deformation of the nozzle lower to 0.35 mm. The equivalent stress of most parts is controlled under 360 MPa. Then, the powder flows of the inner and outer rings of the multiple powder feeding channels are simulated in Ansys Fluent. The convergence effect of the powder flow could be assumed and some significant parameters, such as the velocity, are acquired. The results present that these multiple powder feeding channels could realize the generation and removal of removable supports of workpieces with highly complex shapes and achieve a large processing range and good processing efficiency. The velocity of the powder flow at the outlet is elevated to about 5 mm/s. Then, the thermal cladding states under the new laser heat source of the powder are simulated in Workbench. The temperature of the melting process and the thermal deformation and the equivalent stress/strain of the additive parts are obtained in the emulation. The results emerge that the powder melting range and the ascending temperature of the melting pool are improved with this effect. The greatest temperature of the melting pool is about 2900 °C in the machining process, and the maximum thermal equivalent stress is 1.1407 × 1010 Pa.
Highlights
Through simulations of water cooling and without water cooling, it can be found that the water cooling had a good control and showed a reduction on the effect of temperature control, deformation of thermal stress, and equivalent stress and strain of the thermal stress
After designing a new type of laser cladding nozzle, we finished the simulations of the loop-type water cooling channels, and comparative analysis showed that the loop-type water cooling channels had an excellent cooling effect
The nozzle uses a new kind of laser with one beam inside and three beams outside as a heat source
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. The existing coaxial powder feeding method has some shortcomkind of nozzle, which could achieve a high efficiency andobvious high quality, and that ings incomplete terms of the workpieces, with more stringentrequirements, quality requirements. Simulations, processing timethe of the coaxial powder feeding method was long, complicated which include temperature distribution and thermal deformation ofworkpieces a new nozzle in were difficult to process, and the workpiece strength was insufficient. The powder flow convergence kind of cladding nozzle, which could achieve a high efficiency and high quality, and that iscould shown in the simulations; these results are very important to present the machining complete highly complicated machining requirements, is necessary. The research, we could get theand results forunnecessary a cladding nozzle working state and the quality of the additive part under a new kind of laser.
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