Numerical Simulation of Transient Multiphase Field During Hybrid Plasma-Laser Deposition Manufacturing
Numerical Simulation of Transient Multiphase Field During Hybrid Plasma-Laser Deposition Manufacturing
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DOI：
10.1115/1.2969749
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发表时间：
2008-11
影响因子：
--
通讯作者：
F. Kong;Haiou Zhang;Guilan Wang
中科院分区：
文献类型：
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作者：
F. Kong;Haiou Zhang;Guilan Wang
等离子体-激光复合沉积制造(PLDM)工艺是在等离子体沉积制造(PDM)技术的基础上发展起来的。PLDM属于三维(3D)焊接技术，涉及激光功率作为增强热源。与产品数据管理技术相比，PLDM技术具有更高的功率密度、更高的加工精度、更细小的显微组织和更好的成形零件的力学性能。由于PLDM与快速熔化和凝固过程相结合，存在着复杂的物理和冶金相互作用机制。此外，激光与等离子弧间的相互作用也直接影响到三维金属零件的成形质量和精度。因此，本文对PLDM过程中的传输现象进行了初步的研究，对PLDM过程中的传热、流体流动和熔体粉末沉积过程进行了详细的研究。在对算法进行适当修改后，采用基于压力的有限体积差分技术进行了数值研究。采用热容-气孔法模拟固/液相变过程，采用Level-Set方法跟踪送粉熔敷层焊缝表面的演变过程。建立了一个基于实验的混合热输入模型，该模型考虑了激光与弧光等离子体的相互作用对材料再分配能量吸收的影响。使用与计算相同的参数对PLDM过程进行了相应的实验，显示出良好的定性一致性。
The hybrid plasma-laser deposition manufacturing (PLDM) process is developed based on the plasma deposition manufacturing (PDM) technology. PLDM belongs to the three-dimensional (3D) welding technology and involves the laser power as an augmented heat resource. Compared to PDM technology, the PLDM process has many advantages such as a higher power density, higher processing precision, refined microstructure, and improved mechanical performance of forming components. There exist complicated physical and metallurgical interaction mechanisms due to the combination of PLDM along with the rapid melting and solidification process. Moreover, the interaction between the laser and plasma arc also directly influences the forming quality and precision of the 3D metal components. Therefore, the proposed work is a preliminary attempt to study the transport phenomena in the PLDM process, in which the heat transfer, fluid flow, and molten powder depositing processes have been investigated in detail. The numerical study is performed by using a pressure-based finite volume difference technique after making appropriate modifications of the algorithm. The associated solid/liquid phase transformation process is involved by using an enthalpy-porosity method, and the level-set approach is introduced to track the evolution of weld surface of the deposition layer with powder feeding. An experimentally based hybrid heat input model is developed to involve the influence of the interaction of laser and arc plasma on the redistributed energy absorption by the material. Corresponding experiments of the PLDM process are performed using the same parameters as in the computations, showing a good qualitative agreement.