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Research Papers: Heat Transfer in Manufacturing

Numerical Simulation of Transient Multiphase Field During Hybrid Plasma-Laser Deposition Manufacturing

[+] Author and Article Information
Fanrong Kong

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan City 430074, P.R.C.

Haiou Zhang1

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan City 430074, P.R.C.zholab@mail.hust.edu.cn

Guilan Wang

State Key Laboratory of Material Forming and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan City 430074, P.R.C.

1

Corresponding author.

J. Heat Transfer 130(11), 112101 (Sep 02, 2008) (7 pages) doi:10.1115/1.2969749 History: Received May 23, 2007; Revised May 12, 2008; Published September 02, 2008

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.

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Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 1

Sketch map of the PLDM process

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Figure 2

Schematic of the level-set approach

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Figure 3

Flowchart of the solution procedure in each time step

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Figure 4

Transient temperature distribution during PLDM (h=0mm): (a) t=0.5s, (b) t=2s, and (c) t=5s

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Figure 5

Fluid flow in the molten pool during the PLDM (h=0mm): (a) t=0.5s, (b) t=2s, and (c) t=5s

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Figure 6

Plasma shapes of hybrid welding with different standoff distances DLA=1mm, 2mm, 3mm, 4mm, 5mm, and 6mm, respectively (see Ref. 18)

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Figure 7

Sketch map of the PLDM process with different hybrid heat source distributions

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Figure 8

Temperature distribution in the PLDM with different off-distances at the moment t=0.2s: (a) h=0mm, (b) h=3mm, and (c) h=6mm

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Figure 9

Fluid flow in the molten pool during the PLDM process with different off-distances at the moment t=0.4s: (a) h=0mm, (b) h=3mm, and (c) h=6mm

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Figure 10

Evolution of maximum temperature in the molten pool during the PLDM

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Figure 11

Evolution of the depth of molten pool during the PLDM

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Figure 12

Evolution of the length of the molten pool during the PLDM

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Figure 13

Measurement values (4) and numerical simulation of the molten pool depth during the PLDM (h=0mm)

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