Numerical Simulation of Powder Flow-Melt Pool Coupling in Laser Cladding Process.
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| Title: | Numerical Simulation of Powder Flow-Melt Pool Coupling in Laser Cladding Process. |
|---|---|
| Authors: | Wang, Tao1 (AUTHOR), Wang, CuiFeng1 (AUTHOR), Liao, XiaoLing1 (AUTHOR) 110587@fjpit.edu.cn |
| Source: | Journal of Materials Engineering & Performance. May2026, Vol. 35 Issue 17, p17315-17331. 17p. |
| Subjects: | Computational fluid dynamics, Level set methods, Laser deposition, Granular flow, Computer simulation, Heat transfer, Marangoni effect |
| Abstract: | Laser cladding involves complex powder-gas-light coupling during powder feeding and heat/mass transfer during molten pool formation. Existing numerical studies typically treat these stages separately, limiting predictive accuracy when powder flow parameters vary. This study presents a coupled numerical framework that explicitly links powder flow characteristics to molten pool dynamics through physics-based source terms. Computational fluid dynamics simulations of the powder flow field were conducted across varying jet velocities (16–18 m/s) and laser powers (1000–1300 W). From these results, empirical Gaussian distribution equations were derived to describe powder concentration (r2 = 0.9948), temperature (r2 = 0.7889), and velocity (r2 = 0.9232) distributions. These equations serve as spatially resolved mass, energy, and momentum source terms for the molten pool model, which employs the Level-Set method for interface tracking and accounts for Marangoni convection. Experimental validation using high-speed imaging and infrared thermography demonstrates strong agreement: cladding layer height predictions achieve errors ≤ 5%, temperature distributions match within experimental uncertainty, and flow patterns align with observed molten pool morphology. The validated model reveals that jet velocity primarily controls powder concentration and cladding height, while laser power dominates temperature gradients and Marangoni-driven convection intensity. [ABSTRACT FROM AUTHOR] |
| Copyright of Journal of Materials Engineering & Performance is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
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| Header | DbId: egs DbLabel: Engineering Source An: 193629263 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Numerical Simulation of Powder Flow-Melt Pool Coupling in Laser Cladding Process. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Wang%2C+Tao%22">Wang, Tao</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+CuiFeng%22">Wang, CuiFeng</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Liao%2C+XiaoLing%22">Liao, XiaoLing</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> 110587@fjpit.edu.cn</i> – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Journal+of+Materials+Engineering+%26+Performance%22">Journal of Materials Engineering & Performance</searchLink>. May2026, Vol. 35 Issue 17, p17315-17331. 17p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Computational+fluid+dynamics%22">Computational fluid dynamics</searchLink><br /><searchLink fieldCode="DE" term="%22Level+set+methods%22">Level set methods</searchLink><br /><searchLink fieldCode="DE" term="%22Laser+deposition%22">Laser deposition</searchLink><br /><searchLink fieldCode="DE" term="%22Granular+flow%22">Granular flow</searchLink><br /><searchLink fieldCode="DE" term="%22Computer+simulation%22">Computer simulation</searchLink><br /><searchLink fieldCode="DE" term="%22Heat+transfer%22">Heat transfer</searchLink><br /><searchLink fieldCode="DE" term="%22Marangoni+effect%22">Marangoni effect</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: Laser cladding involves complex powder-gas-light coupling during powder feeding and heat/mass transfer during molten pool formation. Existing numerical studies typically treat these stages separately, limiting predictive accuracy when powder flow parameters vary. This study presents a coupled numerical framework that explicitly links powder flow characteristics to molten pool dynamics through physics-based source terms. Computational fluid dynamics simulations of the powder flow field were conducted across varying jet velocities (16–18 m/s) and laser powers (1000–1300 W). From these results, empirical Gaussian distribution equations were derived to describe powder concentration (r2 = 0.9948), temperature (r2 = 0.7889), and velocity (r2 = 0.9232) distributions. These equations serve as spatially resolved mass, energy, and momentum source terms for the molten pool model, which employs the Level-Set method for interface tracking and accounts for Marangoni convection. Experimental validation using high-speed imaging and infrared thermography demonstrates strong agreement: cladding layer height predictions achieve errors ≤ 5%, temperature distributions match within experimental uncertainty, and flow patterns align with observed molten pool morphology. The validated model reveals that jet velocity primarily controls powder concentration and cladding height, while laser power dominates temperature gradients and Marangoni-driven convection intensity. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Journal of Materials Engineering & Performance is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1007/s11665-025-12845-4 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 17 StartPage: 17315 Subjects: – SubjectFull: Computational fluid dynamics Type: general – SubjectFull: Level set methods Type: general – SubjectFull: Laser deposition Type: general – SubjectFull: Granular flow Type: general – SubjectFull: Computer simulation Type: general – SubjectFull: Heat transfer Type: general – SubjectFull: Marangoni effect Type: general Titles: – TitleFull: Numerical Simulation of Powder Flow-Melt Pool Coupling in Laser Cladding Process. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Wang, Tao – PersonEntity: Name: NameFull: Wang, CuiFeng – PersonEntity: Name: NameFull: Liao, XiaoLing IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 05 Text: May2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 10599495 Numbering: – Type: volume Value: 35 – Type: issue Value: 17 Titles: – TitleFull: Journal of Materials Engineering & Performance Type: main |
| ResultId | 1 |
