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Dimensional and material characteristics of direct deposited H13 tool steel by C O 2 laser
J. Laser Appl. 16, 245 (2004); 10.2351/1.1809638
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JOURNAL OF LASER APPLICATIONS VOLUME 10, NUMBER 2 APRIL 1998
Key words: coaxial nozzle, laser cladding, catchment efficiency, powder flow
INTRODUCTION shielding gas on the jet flow and the catchment efficiency
was analyzed by both theory and experiments. Flow visuali-
The laser cladding process has been investigated over sation with image analysis is used to check this simulation
the past decades. It is one of the advanced techniques for and some initial studies are reported on the effects of flow
surface treatment possible with a laser.1 In laser cladding the parameters on the catchment efficiency and degree of powder
clad layer can be applied as a powder, foil, or wire with the focus. The powder used in the tests was stainless steel 304L
objective of improving the corrosion, wear, or cosmetic powder. Clad trials were performed on a mild steel substrate
properties of the object being clad as well as applications with a 1.0 kW cw CO2 laser with a constant table speed of 10
such as repair and rebuild. In powder systems the powder mm/s.
can be preplaced or blown into the laser generated melt pool.
The blown powder route is one of the rare processes which is
capable of giving a fused bond with low dilution over large COAXIAL CLADDING NOZZLE
or small areas. It has thus found applications in industry and
is the subject of much research around the world. Most work The design of the coaxial nozzle structure is illustrated
to date has used an off axis powder feed system to avoid the in Fig. 1. The design specification included compact size,
powder melting and sticking to the feed nozzle or oxidizing efficient energy interaction between the laser beam and the
prior to cladding. However a coaxial feed would make this powder outside the nozzle assembly, and shrouded gas flow
promising process omnidirectional and therefore easier to which would tend to focus the powder stream.
use. This would open up new possibilities for repair and for The nozzle is composed of three separate parts: the cen-
the newly developed laser direct casting process ~LDC!.2–4 tral hole through which the laser beam and shield gases pass;
In this new technique, three-dimensional ~3D! metal compo- the surrounding annular zone into which the powder flows
nents can be directly built from a computer aided design and is blown out by its carrier gas as a cone into the laser
~CAD! drawing, suggesting a new route for low volume beam outside the nozzle; and an outer annular gas jet. The
manufacturing. beam focus is set at the nozzle exit so that the powder inter-
Some attempts have been made to operate coaxial pow- acts with an expanding beam whose focal length is 150 mm
der feeders in which the powder interacts with the beam just ~;8° divergence!. An inert gas, such as argon, is blown
outside the nozzle or to feed the powder from symmetrically through the inner and the outer nozzles to protect the focus-
placed external pipes creating a central powder flow.5,6 ing lens and prevent powder oxidation. A water jacket was
These systems gave a coaxial feed but with poor powder used to remove the heat from the nozzle for a prolonged
focus or some solidification within the nozzle assembly. working life.
There was also a problem with the heat balance during pro-
longed periods of processing.
In this article a novel coaxial design is studied. The de- FLOW VISUALIZATION
sign has been successfully used for LDC and behaves as a
‘‘metal pencil,’’ capable of making uniform deposits in any Two methods were used to visualize the powder stream
direction. In this article the nozzle characteristics are deter- coming from the coaxial nozzle. The first method filmed the
mined through a numerical simulation. The influence of the light scattered from an incident 2D light beam which illumi-
FIG. 5. Signal output from powder scanning sensor at the inner jet velocity
of ~a! U 0 52 m/s, U 1 52 m/s; ~b! U 0 54 m/s, U 1 52 m/s.
FIG. 6. Normalized concentration distribution from ~a! scanning powder FIG. 7. The stream angle change with variable velocity of the compound
sensor, ~b! CCD camera to assure a Gaussian mode of the powder stream jets for ~a! cold stream, ~b! hot stream.
spraying.
FIG. 9. The influence of the compound jets velocity on the distribution of powder concentration along the stream radial direction.
THERMAL PROFILE IN THE POWDER STREAM ing heating. This implies an infinite thermal conductiv-
ity, k, such that k@h, where h is the particle to gas heat
The process to be modeled consists of a stream of pow- transfer coefficient.
der particles falling in an expanding laser beam. The power ~3! Latent heat effect is neglected in this analysis.
distribution within the laser beam will be one of the specified
structures, typically Gaussian mode, and thus a given particle In general, the motion of the particle is determined by the
may be subjected to a changing power density as it falls in fluid forces acting on it as described by Eq. ~3!. However this
the beam. On impact with the substrate to be clad, the par- ignores the heating effects of the gas adjacent to the particle
ticle will either adhere and form a clad or bounce off. The which would in practice cause significant gas expansion af-
mechanism determining which event occurs is not clearly fecting its velocity and direction
understood but is expected to include whether the particle or dV 3 m C D Re
the substrate or both are molten. It is felt that a solid/solid 5 ~ U2V ! 1g. ~3!
interaction will most probably result in a ricochet. The one dt 4 r p D 2p
exception could be that the substrate is sufficiently hot to The drag coefficient C D of the flow is expressed in Eq. ~4!
melt the particle during the impact time. Thus the points of for Re,1000:
interest in this system for laser cladding are the distance from
the nozzle at which the powder melts, the temperature of the 24
C D5 ~ 110.15 Re1.687! . ~4!
particle and substrate at the impact point, and the velocity of Re
the particle upon impact.
Some modeling of such problems has been done for the The Reynolds number, Re, is defined in the usual way in Eq.
plasma spraying process10 and little for the laser cladding. ~5!:
Some of this analytic work included solving the equations of r u U2V u D p
conservation for mass, momentum, and energy at high tem- Re5 . ~5!
m
peratures. This level of analysis was not considered neces-
sary for this problem. Here a simplified approach is dis- The change in the particle temperature is obtained from an
cussed to solve the thermal profile of the coaxial powder energy balance on the particle as expressed in Eq. ~6!:
stream based on the following assumptions:
dT p 6Nuk 3eI
~1! The particle is spherical with constant absorptivity to 5 2 ~ T g 2T p ! 1 . ~6!
dt D pr pC p 2 r pD pC p
10.6 mm radiation and is moving in a uniform jet flow
and a uniform radiation field. The Nusselt number for a spherical particle moving in a gas
~2! The internal temperature of the particle is uniform dur- stream is expressed as Nu5210.6Re0.5Pr0.33. 10 The geomet-
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60 J. Laser Appl., Vol. 10, No. 2, April 1998 J. Lin and W. M. Steen
F SD G
I5 . ~7!
w d8 2 is heated by the optical energy. Its temperature can reach as
p tan S1 high as a few thousand degree Kelvin depending on the op-
2 2
erating conditions, the thermal properties, the size and the
As an example, the beam power of 1 kW with absorptivity of velocity of the particle, and the gas velocity in the jet flow.
0.4 on a stainless steel particle of 75 mm and initial velocity According to Planck’s law,11 the heated surface will radiate
V 0 52 m/s under varying inner jet velocity was used. The over a wide range of wavelengths depending on the surface
calculated results of a moving particle under laser radiation temperature and emissivity. Here we assume the particle be-
are shown in Fig. 10. It could be found that particle heating haves as a grey body. The radiation energy detected by the
is mainly determined by the beam focus of the laser radia- photodiode on the particle surface will correlate to its
FIG. 11. ~a! Particle temperature measured by a pin-hole photo detector. ~b! Calculated temperature of the tungsten lamp with various electric power input.
~c! The voltage response of the photo diode with various lamp temperatures.
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J. Laser Appl., Vol. 10, No. 2, April 1998 J. Lin and W. M. Steen 61
angle. It is seen that the spraying angle and the initial diam-
eters of the powder and laser beam will significantly affect
the catchment efficiency. In our case, the reduction of the
spraying angle, which is controlled by the velocity of the
compound jets, will increase the catchment efficiency up to
40% at the spraying angle of about 10° for both inner and
outer gas velocities of 2 m/s.
CONCLUSIONS
This study demonstrates a nozzle design to improve jet
spraying on clad surfaces. The omnidirectional ability of the
coaxial nozzle will provide a possible technique for rapid
FIG. 13. The relationship between the powder catchment efficiency and the
prototyping applications. The interaction between the laser
diameter ratio d/D of the clad to powder stream for Gaussian mode distri- beam and the powder concentration should be strictly con-
bution. trolled to achieve an efficient cladding process. The control-
ling of the exit jet of the powder stream is seen as a possible
way to improve its efficiency.
h SD
d
D
5
* z d f ~ z ! pz d z
* z D f ~ z ! pz d z
, ~10!
The Gaussian mode of the powder distribution in coaxial
cladding jet flow was obtained by both experimental and
numerical approaches. Further evidence from the photosen-
where z d 5d/ s and z D 5D/ s , s is the stream diameter cov- sor and plane beam image analysis supported the same con-
ering a portion of 68% of the concentration in the section clusion. This provided a basic distribution of the powder
plane. stream to estimate the catchment efficiency as a function of
Equation ~9! can be rearranged as Eq. ~10! if a stream the shield gas effects.
diameter is selected as D53 s ( z D 53). This new definition The theoretical study of the single particle heating in a
of the stream diameter will cover 99.8% of the concentration laser beam was verified by the temperature measurement ob-
in the section plane and it will be much more accurate in the tained using a pin-hole sensor. The thermal profile of the
calculation of catchment efficiency using the Gaussian dis- powder stream determines the stand-off distance for a proper
tribution mode clad setting. This melting distance is a strong function of the
2 laser power and flow rate.
h 512e 22 z d . ~11! The velocity of the compound jet will determine the
The numerical relationship of Eq. ~11! between the catch- stream shape and hence the catchment efficiency. The melt
ment efficiency and the diameter ratio (d/D) of the clad to pool arising from the laser spot will have a diameter propor-
the powder stream is shown in Fig. 13. It can be found that tional to the beam diameter up to the point where the power
the catchment efficiency will be increased with d/D and ap- density fails to melt. This will give a peak value in the pow-
proaches 80% at d/D51.5. In our optics setting and nozzle der catchment as a function of the stand-off distance for
size the d 8 /D 8 is about 0.26 and it could be substituted in small spraying angles. Considering the Gaussian distribu-
Eq. ~8! to calculate the value of d/D through the beam axis. tions of the powder streams, it gives an approximated for-
An important relationship between the catchment efficiency mula for the catchment efficiency h up to 40% in our nozzle
and geometric parameters of stand-off distance and spraying design. This formula was verified by experimental measure-
angle was established in Fig. 14. The catchment efficiency is ments.
compared to the experimental data with varying spraying
ACKNOWLEDGMENTS
Many thanks are due to Dr. W. O’Neill and Dr. G.
Shannon of the University of Liverpool for their invaluable
suggestions to this work, which is under the LEMA ~Laser
Engineering for Manufacturing Applications! project spon-
sored by EPSRC, UK.
NOMENCLATURE
A: mean particle cross section area of the particles
CD : drag coefficient of the flow
cp : particle specific heat
Dp : particle diameter
d: laser beam diameter
D: powder stream diameter
FIG. 14. The effect of the stream angle on the catchment efficiency for both d 8: effective initial beam diameter
theoretical and experimental approaches. D 8: effective initial stream diameter
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J. Laser Appl., Vol. 10, No. 2, April 1998 J. Lin and W. M. Steen 63
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