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Chinese Journal of Lasers, Volume. 51, Issue 24, 2402301(2024)

Simulation of Coaxial Powder Feeding Laser Directed Energy Deposition of AlCoCrFeNi High Entropy Alloys Based on DPM‐VOF Method

Guangyi Ma*, Hongyu Wang, Shiyong Ma, Tengda Di, Fangyong Niu, and Dongjiang Wu
Author Affiliations
  • State Key Laboratory of High-Performance Precision Manufacturing, Dalian University of Technology, Dalian 116024, Liaoning , China
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    AbstractGet PDF(in Chinese)
    Figures&Tables (24)
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    References (33)
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    Figures & Tables(24)
    Schematic diagram of laser directed energy deposition system

    Fig. 1. Schematic diagram of laser directed energy deposition system

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    Schematic of the VOF method for tracing the free surface of fluid

    Fig. 2. Schematic of the VOF method for tracing the free surface of fluid

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    Particle model. (a) DPM model; (b) DPM-VOF coupled model

    Fig. 3. Particle model. (a) DPM model; (b) DPM-VOF coupled model

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    Energy distribution of heat sources in rotating Gaussian bodies

    Fig. 4. Energy distribution of heat sources in rotating Gaussian bodies

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    Adaptive heat source modeling

    Fig. 5. Adaptive heat source modeling

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    Computational domain. (a) Physical model; (b) mesh

    Fig. 6. Computational domain. (a) Physical model; (b) mesh

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    Single-track deposition. (a) Experimental results; (b) simulation results; (c) cross-section size comparison; (d) deposition height during stable molding; (e) deposition width during stable molding

    Fig. 7. Single-track deposition. (a) Experimental results; (b) simulation results; (c) cross-section size comparison; (d) deposition height during stable molding; (e) deposition width during stable molding

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    Temperature field characteristics of the melt pool. (a) Temperature field at 0.1 s; (b) temperature field at 0.5 s; (c) temperature field at 1.5 s; (d) temperature field at 3.0 s; (e) melt pool volume versus time; (f) max temperature of melt pool versus time

    Fig. 8. Temperature field characteristics of the melt pool. (a) Temperature field at 0.1 s; (b) temperature field at 0.5 s; (c) temperature field at 1.5 s; (d) temperature field at 3.0 s; (e) melt pool volume versus time; (f) max temperature of melt pool versus time

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    Flow characteristics of the melt pool moments. (a) 0.1 s; (b) 0.5 s; (c) 1.5 s; (d) 3.0 s

    Fig. 9. Flow characteristics of the melt pool moments. (a) 0.1 s; (b) 0.5 s; (c) 1.5 s; (d) 3.0 s

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    Flow field distribution in the longitudinal section of the melt pool moments. (a) 3.00018 s; (b) 3.00019 s; (c) 3.00020 s; (d) 3.00021 s; (e) 3.00022 s; (f) 3.00023 s; (g) 3.00038 s; (h) 3.00039 s

    Fig. 10. Flow field distribution in the longitudinal section of the melt pool moments. (a) 3.00018 s; (b) 3.00019 s; (c) 3.00020 s; (d) 3.00021 s; (e) 3.00022 s; (f) 3.00023 s; (g) 3.00038 s; (h) 3.00039 s

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    Cross-sectional flow field distributions at different locations of the melt pool. (a1)‒(a4) Back edge of the melt pool;

    Fig. 11. Cross-sectional flow field distributions at different locations of the melt pool. (a1)‒(a4) Back edge of the melt pool;

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    Temperature distributions of the deposition layer moments. (a) 7.5 s; (b) 12.5 s; (c) 17.5 s; (d) 20.0 s

    Fig. 12. Temperature distributions of the deposition layer moments. (a) 7.5 s; (b) 12.5 s; (c) 17.5 s; (d) 20.0 s

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    Melt pool morphology at different moments. (a) 2.5 s; (b) 7.5 s; (c) 12.5 s; (d) 17.5 s

    Fig. 13. Melt pool morphology at different moments. (a) 2.5 s; (b) 7.5 s; (c) 12.5 s; (d) 17.5 s

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    Temperature gradient along the solid-liquid interface behind the melt pool at different moments. (a) 2.5 s; (b) 7.5 s; (c) 12.5 s; (d) 17.5 s

    Fig. 14. Temperature gradient along the solid-liquid interface behind the melt pool at different moments. (a) 2.5 s; (b) 7.5 s; (c) 12.5 s; (d) 17.5 s

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    Melt pool movement process in different sedimentary layers

    Fig. 15. Melt pool movement process in different sedimentary layers

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    Solidification rates along the solid‒liquid interface behind the melt pool at different moments. (a) 2.5 s; (b) 7.5 s; (c) 12.5 s; (d) 17.5 s

    Fig. 16. Solidification rates along the solid‒liquid interface behind the melt pool at different moments. (a) 2.5 s; (b) 7.5 s; (c) 12.5 s; (d) 17.5 s

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    Microstructures of thin-walled specimen. (a) Bottom; (b) middle; (c) top

    Fig. 17. Microstructures of thin-walled specimen. (a) Bottom; (b) middle; (c) top

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    • Table 1. Chemical composition of AlCoCrFeNi HEA powder

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      Table 1. Chemical composition of AlCoCrFeNi HEA powder

      ElementMass fraction /%
      Al10.35
      Co23.11
      Cr20.26
      Fe22.49
      NiBal.
      O0.0071
      N0.0094

    • Table 2. Quantity fraction in diameter range of AlCoCrFeNi HEA powder

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      Table 2. Quantity fraction in diameter range of AlCoCrFeNi HEA powder

      Diameter range /μmQuantity fraction /%
      ≤457.2
      >45‒6027.0
      >60‒7543.0
      >75‒9014.6
      >908.2

    • Table 3. Sample molding process parameters

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      Table 3. Sample molding process parameters

      SampleScanning path

      Laser

      power/W

      Scanning velocity /

      （mm/min）

      Powder feeding

      rate /（g/min）

      Number of

      deposition layers

      Interlayer lifting

      height /mm

      Single-track6001202.581
      Thin-walledReciprocating scanning6001202.5840.8

    • Table 4. Specific parameters in DPM model

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      Table 4. Specific parameters in DPM model

      ParameterValue
      Powder diameter dp /μm45‒90
      Initial velocity of powder vPs /（m/s）0.8
      Initial temperature of powder TPs /K1600
      Powder utilization rate np0.53‒0.71

    • Table 5. Numerical model parameters

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      Table 5. Numerical model parameters

      ParameterValue
      Laser beam radius at work plane r0 /m0.001
      Laser focusing radius rf /m0.0005
      Defocuse distance of work plane f /m0.0167
      Depth of the laser heat source H0 /m0.001
      Laser energy absorptivity nq0.3
      Ambient temperature T0 /K300

    • Table 6. Thermal-physical parameters of AlCoCrFeNi HEA

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      Table 6. Thermal-physical parameters of AlCoCrFeNi HEA

      ParameterValue
      Density ρ /（kg/m3）7070
      Thermal expansion coefficient β /K-12.3×10-5
      Dynamic viscosity μ /［kg/（m·s）］6.72×10-3
      Solidus temperature TS /K1413
      Liquidus temperature TL /K1523
      Specific heat c /［J/（kg·K）］739
      Latent heat of fusion L /（kJ/kg）230
      Thermal conductivity k /［W/（m·K）］29.3
      Convective heat transfer coefficient hc /［W/（m2·K）］25
      Surface tension coefficient σ /（N/m）1.79
      Temperature coefficient of surface tension dσ/dT /［N/（m·K）］-2.5×10-4

    • Table 7. G/R values along the solid‒liquid interface behind the melt pool at different moments

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      Table 7. G/R values along the solid‒liquid interface behind the melt pool at different moments

      TimeAverage G/R value
      2.5 s （1st layer）5.16×109
      7.5 s （2nd layer）1.89×109
      12.5 s （3rd layer）1.27×109
      17.5 s （4th layer）1.06×109
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    Guangyi Ma, Hongyu Wang, Shiyong Ma, Tengda Di, Fangyong Niu, Dongjiang Wu. Simulation of Coaxial Powder Feeding Laser Directed Energy Deposition of AlCoCrFeNi High Entropy Alloys Based on DPM‐VOF Method[J]. Chinese Journal of Lasers, 2024, 51(24): 2402301

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    Paper Information

    Category: Laser Additive Manufacturing

    Received: Apr. 24, 2024

    Accepted: Jun. 17, 2024

    Published Online: Dec. 11, 2024

    The Author Email: Ma Guangyi (gyma@dlut.edu.cn)

    DOI:10.3788/CJL240809

    CSTR:32183.14.CJL240809

    Topics

    laser devices and laser physics
    Lasers and Laser Optics
    Laser physics
    laser manufacturing
    Instrumentation, Measurement and Metrology