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同轴送粉激光熔覆的粉末熔化过程建模与仿真

Detection and analysis of melting behavior of powder coaxially fed laser

  • 摘要: 同轴送粉激光熔覆中,粉末与激光的交互作用会直接影响熔覆成形的精度与质量,红外摄像无法直接获得激光内粉末的熔化行为,因此通过分析粉末对热量的吸收情况,使用高速摄像系统采集粉末熔化的动态行为,并建立粉末熔化过程的动态解析模型, 通过仿真分析激光功率对不同熔化阶段的影响,及粉末进入熔池时的温度特征. 结果表明,高速摄像系统采集粉末在激光中的动态熔化行为中存在“固态→固液两相态→液态”3 个典型熔化特征阶段,粉末熔化动态行为可以使用数学解析模型解析,而不同阶段的热物理行为具有粉末与激光热交互作用的动态解析模型,分析了激光功率、离焦量、载粉气流量对粉末熔化行为的影响,同时通过仿真分析不同激光功率对各个特征阶段持续时间的影响,预测粉末颗粒到达基材的温度分布,发现激光功率从 100 W 增加至 1 500 W 时,粉末进入熔池的温度呈非线性变化,温度从750 ℃增加至 3 250 ℃.

     

    Abstract: During coaxial powder laser coating, the interaction between powder and laser directly affects the forming accuracy and quality of cladding. It is impossible to directly obtain the melting behavior of powder in laser and analyze the heat absorption of powder by infrared camera. Therefore, by analyzing the absorption of heat by powder, the dynamic behavior of powder melting was collected by high-speed camera system and the dynamic analytical model of powder melting process was established. The influence of laser power on different melting stages and the temperature characteristics of powder entering molten pool were simulated and analyzed. The results show that the dynamic melting behavior of the powder in the laser of the high-speed camera acquisition system has three typical melting characteristic stages of 'solid → solid-liquid two-phase → liquid'. The dynamic behavior of powder melting can be analyzed by mathematical analytical model, and the thermal physical behavior of different stages has a dynamic analytical model of the interaction between powder and laser heat. The effects of laser power, off-focus value and the flow rate of the gas carrying the powder on the melting behavior of powder were analyzed. At the same time, the effects of different laser power on the duration of each characteristic stage were simulated and analyzed, and the temperature distribution of powder particles reaching the substrate was predicted. It was found that when the laser power increased from 100 W to 1500 W, the temperature of the powder entering the molten pool changed nonlinearly, and the temperature increased from 750 ℃ to 3 250 ℃.

     

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