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Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts
Since shaft parts operate under harsh environments for a long time, many critical parts suffer from corrosion, wear and other problems, leading to part failure and inability to continue in service. It is imperative to repair failed parts and increase their service life. An orthogonal experimental sc...
Autores principales: | , , , , , , |
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Formato: | Online Artículo Texto |
Lenguaje: | English |
Publicado: |
MDPI
2023
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Materias: | |
Acceso en línea: | https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9965465/ https://www.ncbi.nlm.nih.gov/pubmed/36838193 http://dx.doi.org/10.3390/mi14020493 |
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author | Zhao, Changlong Ma, Chen Yang, Junbao Li, Ming Zhao, Qinxiang Ma, Hongnan Jia, Xiaoyu |
author_facet | Zhao, Changlong Ma, Chen Yang, Junbao Li, Ming Zhao, Qinxiang Ma, Hongnan Jia, Xiaoyu |
author_sort | Zhao, Changlong |
collection | PubMed |
description | Since shaft parts operate under harsh environments for a long time, many critical parts suffer from corrosion, wear and other problems, leading to part failure and inability to continue in service. It is imperative to repair failed parts and increase their service life. An orthogonal experimental scheme is designed to numerically simulate the process of laser cladding of Inconel 718 alloy powder on 4140 alloy structural steel based on the ANSYS simulation platform, derive the relationship equation of cladding layer thickness according to the heat balance principle, establish a finite element model, couple three modules of temperature field, stress field and fluid field, and analyze different modules to realize the monitoring of different processes of laser cladding. The optimal cladding parameters were laser power 1000 W, scanning speed 15 rad/s, spot radius 1.5 mm, thermal stress maximum value of 696 Mpa, residual stress minimum value of 281 Mpa, and the degree of influence of three factors on thermal stress maximum value: laser power > spot radius > scanning speed. The pool in the melting process appears to melt the “sharp corner” phenomenon, the internal shows a double vortex effect, with a maximum flow rate of 0.02 m/s. The solidification process shows a different shape at each stage due to the different driving forces. In this paper, multi-field-coupled numerical simulations of the laser cladding process were performed to obtain optimal cladding parameters with low residual stresses in the clad layer. The melt pool grows and expands gradually during melting, but the laser loading time is limited, and the size and shape of the melt pool are eventually fixed, and there is a vortex flowing from the center to both sides of the cross-section inside the melt pool, forming a double vortex effect. The solidification is divided into four stages to complete the transformation of the liquid phase of the melt pool to the solid phase, and the cladding layer is formed. The multi-field-coupled numerical simulation technique is used to analyze the temperature, stress and fluid fields to provide a theoretical basis for the residual stress and surface quality of the clad layer for subsequent laser cladding experiments. |
format | Online Article Text |
id | pubmed-9965465 |
institution | National Center for Biotechnology Information |
language | English |
publishDate | 2023 |
publisher | MDPI |
record_format | MEDLINE/PubMed |
spelling | pubmed-99654652023-02-26 Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts Zhao, Changlong Ma, Chen Yang, Junbao Li, Ming Zhao, Qinxiang Ma, Hongnan Jia, Xiaoyu Micromachines (Basel) Article Since shaft parts operate under harsh environments for a long time, many critical parts suffer from corrosion, wear and other problems, leading to part failure and inability to continue in service. It is imperative to repair failed parts and increase their service life. An orthogonal experimental scheme is designed to numerically simulate the process of laser cladding of Inconel 718 alloy powder on 4140 alloy structural steel based on the ANSYS simulation platform, derive the relationship equation of cladding layer thickness according to the heat balance principle, establish a finite element model, couple three modules of temperature field, stress field and fluid field, and analyze different modules to realize the monitoring of different processes of laser cladding. The optimal cladding parameters were laser power 1000 W, scanning speed 15 rad/s, spot radius 1.5 mm, thermal stress maximum value of 696 Mpa, residual stress minimum value of 281 Mpa, and the degree of influence of three factors on thermal stress maximum value: laser power > spot radius > scanning speed. The pool in the melting process appears to melt the “sharp corner” phenomenon, the internal shows a double vortex effect, with a maximum flow rate of 0.02 m/s. The solidification process shows a different shape at each stage due to the different driving forces. In this paper, multi-field-coupled numerical simulations of the laser cladding process were performed to obtain optimal cladding parameters with low residual stresses in the clad layer. The melt pool grows and expands gradually during melting, but the laser loading time is limited, and the size and shape of the melt pool are eventually fixed, and there is a vortex flowing from the center to both sides of the cross-section inside the melt pool, forming a double vortex effect. The solidification is divided into four stages to complete the transformation of the liquid phase of the melt pool to the solid phase, and the cladding layer is formed. The multi-field-coupled numerical simulation technique is used to analyze the temperature, stress and fluid fields to provide a theoretical basis for the residual stress and surface quality of the clad layer for subsequent laser cladding experiments. MDPI 2023-02-20 /pmc/articles/PMC9965465/ /pubmed/36838193 http://dx.doi.org/10.3390/mi14020493 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/). |
spellingShingle | Article Zhao, Changlong Ma, Chen Yang, Junbao Li, Ming Zhao, Qinxiang Ma, Hongnan Jia, Xiaoyu Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts |
title | Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts |
title_full | Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts |
title_fullStr | Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts |
title_full_unstemmed | Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts |
title_short | Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts |
title_sort | numerical simulation study of multi-field coupling for laser cladding of shaft parts |
topic | Article |
url | https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9965465/ https://www.ncbi.nlm.nih.gov/pubmed/36838193 http://dx.doi.org/10.3390/mi14020493 |
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