Multi-phase flow simulation of powder streaming in laser-based directed energy deposition

As a promising additive manufacturing technique, laser-based directed energy deposition has been widely applied in part fabrication, surface cladding, and part restoration. During the powder feeding process, the gas, particles, and laser interact and further affect the molten pool flow. To study the powder feeding process, a multi-physics gas-particle multi-phase flow model coupled with a laser ray-tracing heat source model is developed to predict the powder particle temperature, velocity, and concentration distribution as well as laser energy loss, which is then validated against experimental results. The single-nozzle simulation shows that powder particles out of the nozzle follow a radial Weibull distribution instead of a 2D Gaussian distribution from the inlet of the nozzle. In the four-nozzle powder feeding process, the particles converge further after passing the focal plane, and setting the focal plane above the molten pool surface could potentially increase the powder catchment. Moreover, the laser ray-tracing model incorporates laser reflection and laser incident angle into laser energy loss calculation, which would be more accurate than those models based on the Beer-Lambert law. Additionally, by increasing the powder feed rate or decreasing the carrier gas flow rate, the laser energy loss linearly increases. The predicted powder velocity, temperature distribution, and attenuated laser can be further implemented into the molten pool flow model to more comprehensively study the interaction between particles and the molten pool in the future. © 2023 The Author(s).