范红丽,齐海波,张钊,韩日宏,刘玉兵.基于CFD-DEM的激光熔覆粉末利用率仿真分析[J].表面技术,2024,53(17):146-156.
FAN Hongli,QI Haibo,ZHANG Zhao,HAN Rihong,LIU Yubing.CFD-DEM Simulation on Powder Catchment Efficiency in Laser Cladding[J].Surface Technology,2024,53(17):146-156 |
| 基于CFD-DEM的激光熔覆粉末利用率仿真分析 |
| CFD-DEM Simulation on Powder Catchment Efficiency in Laser Cladding |
| 投稿时间：2023-10-31 修订日期：2023-12-24 |
| DOI：10.16490/j.cnki.issn.1001-3660.2024.17.013 |
| 中文关键词: 激光熔覆 粉末利用率 CFD-DEM 碰撞 工艺参数 模拟仿真 |
| 英文关键词:laser cladding powder catchment efficiency CFD-DEM collision process parameter simulation |
| 基金项目:河北省自然科学基金(E2023210011，E2022210043) |
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| Author | Institution |
| FAN Hongli | Shijiazhuang Tiedao University, Shijiazhuang 050043, China;Shijiazhuang College of Applied Technology, Shijiazhuang 050800, China |
| QI Haibo | Shijiazhuang Tiedao University, Shijiazhuang 050043, China;Hebei Key Laboratory of Advanced Materials for Transportation Engineering and Environment, Shijiazhuang 050043, China |
| ZHANG Zhao | Shijiazhuang Tiedao University, Shijiazhuang 050043, China |
| HAN Rihong | Shijiazhuang Tiedao University, Shijiazhuang 050043, China;Hebei Key Laboratory of Advanced Materials for Transportation Engineering and Environment, Shijiazhuang 050043, China |
| LIU Yubing | Shijiazhuang Tiedao University, Shijiazhuang 050043, China |
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| 中文摘要: |
| 目的 为准确描述激光熔覆过程中粉末与粉末、送粉管、基板之间存在碰撞的事实，提高粉末利用率，探究送粉量、载气量和保护气量对粉末利用率的影响规律及原因。方法 首先，基于FLUENT有限元分析软件和EDEM离散元分析软件建立基于CFD-DEM的激光熔覆三维耦合模型，对粉末流从喷嘴喷射到达熔池的全过程进行气固两相流模拟仿真;然后，采用正交方差分析法确定送粉量、载气量和保护气量对粉末利用率的影响规律;最后，利用粉末收集试验和单道激光熔覆试验验证模型的可靠性及准确性。结果 粉末利用率方差分析结果表明，送粉量、载气量和保护气量的显著性差异评价量F值分别为169.079、114.317、50.153;粉末利用率随送粉量、载气量和保护气量的增大均先提高后降低;在送粉电压18 V、载气量15 L/min、保护气量10 L/min和送粉电压14 V、载气量11 L/min、保护气量8 L/min 2种极端工况下进行粉末收集试验，模拟值与试验值误差分别为4.03%、4.54%;在激光功率1 100 W、扫描速度5 mm/s下进行单道激光熔覆试验，模拟值与试验值误差分别为16.13%和16.50%，说明该模型准确可靠。结论 送粉量对粉末利用率的影响最大，载气量次之，保护气量影响最小;获取较高粉末利用率的最优组合参数为送粉电压16 V、载气量13 L/min、保护气量10 L/min。 |
| 英文摘要: |
| It is an advanced surface modification technology by laser cladding which has the characteristics of small heat affected zone, fast repair speed and low dilution rate. It is widely used in aerospace, iron and steel metallurgy, marine engineering equipment, engineering machinery, chemical equipment and other important metal parts repair and remanufacturing. In order to accurately describe the fact that there are collisions among powder, powder tube and substrate during powder flow transportation, and improve the powder catchment efficiency, the influence rules and reasons of powder feed rate, carrier gas flow rate and shield gas flow rate are explored. A gas flow model was established in FLUENT finite element analysis software and particle trajectory model in EDEM discrete element analysis software. Then the coupling interface was developed to obtain the CFD-DEM three-dimensional coupling model which could be used to simulate gas-solid two-phase flow for the whole process of powder flow from nozzle to molten pool. The orthogonal table of the SPSS design center was used to conduct 9 sets of simulation to explore the complex interaction mechanism of the three process parameters of powder feed rate, carrier gas flow rate and shield gas flow rate and their influence on the powder catchment efficiency. Finally, the reliability and accuracy of the model were verified by powder collection test and single pass laser cladding experiment. Orthogonal variance analysis of the powder catchment efficiency showed that the significance difference evaluation F of powder feed rate, carrier gas flow rate and shield gas flow rate were 169.079, 114.317, 50.153 respectively, and the powder catchment efficiency increased first and then decreased with the increase of them. When the carrier gas flow was equal to 11 L/min, the powder flow rate was small relatively, and the powder stopped moving after several near-situ collisions on the substrate, so resulting in a low powder catchment efficiency because they were not captured by the molten pool. With the increase of the carrier gas flow to 13 L/min, the rebound force of the powder after reaching the substrate was enhanced, so that the powder that did not enter the molten pool before could be captured, and the powder catchment efficiency was constantly improved. When the carrier gas flow was increased to 15 L/min, low powder convergence caused by the collisions among powder, powder tube and substrate were intensified, thus reducing the powder utilization rate. When the powder feeding voltage was 14 V to 16 V, the collisions and the powder speed changes were few, most of the powder could enter the melt pool and capture smoothly. The higher the powder feeding voltage, the higher powder catchment efficiency. When the powder feeding voltage was increased to 18 V, the powder quantity and collision increased sharply, making many powders deviate from the previous motion path, and the powder catchment efficiency decreased. When the shield gas flow rate was 8 L/min to 10 L/min, the shield gas had a certain collimation effect, which improved the powder convergence and the catchment efficiency. However, when the shield gas flow rate was greater than 10 L/min, they would cause interference to the carrier gas and reduce the powder catchment efficiency. The laser cladding powder collection test was carried out under two extreme working conditions:powder feeding voltage, carrier gas flow rate and shield gas flow rate were 18 V, 15 L/min, 10 L/min and 14 V, 11 L/min, 8 L/min. The single-pass cladding test was carried out under the laser power of 1 100 W and scanning speed of 5 mm/s. The error of the simulated value and the laser cladding collection powder test value were 4.03% and 4.54%, and the single-pass cladding test value were 16.13% and 16.50%, indicating that the model was accurate and reliable. The CFD-DEM three-dimensional coupling model and orthogonal variance analysis of powder catchment efficiency make clear that powder feed rate has significant effect on the powder catchment efficiency, followed by carrier gas flow rate and shield gas flow rate. The optimal combination parameters of powder feeding voltage 16 V, carrier gas flow rate 13 L/min and shield gas flow rate 10 L/min are confirmed. The research results provide theoretical guidance for the selection and optimization of process parameters in laser cladding. |
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