T15高速钢异质材料激光熔覆过程的多相流模型
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摘要
激光熔覆过程中熔池的演变包含能量输入、质量添加、高温金属液体流动、金属熔化凝固以及材料扩散等复杂过程。基于多相流理论,建立了T15高速钢在42CrMo基板上激光熔覆的物质传输模型。其中,质量添加与能量输入过程采用添加在熔池表面单元的源项模拟,而气液界面的捕捉则采用了CLSVOF方法。通过试验获得的熔覆层关键形貌参数,被用来验证数值模型的有效性。结果表明,T15高速钢由于其自身含有较高的硫含量,在激光熔覆熔池中,在Marangoni力的驱动下具有明显内向流动的特征。高温液体向下流动,形成较大的熔深。以熔覆层高度、深度、稀释率等3个形貌参数为比较依据,验证了异质材料激光熔覆的多相流模型,在不同工艺参数组合下试验值与仿真值均具有较好的一致性,证明了该模型可准确反映激光熔覆过程熔池内的微流动与物质传输行为。
During the laser cladding process, the transport phenomenon in the molten pool are complex including intense energy input, mass addition, strong fluid flow, rapid solidification, melting and species transport. In order to simulate the process of depositing T15 powders on 42 CrMo base steel through laser cladding, a multiphase species transport model was developed in which CLSVOF method was adopted to capture the gas-liquid interface and source terms were precisely added under the interface serving as the energy input and mass addition. The model was validated by several characteristic parameters of cladding layers obtained by single track cladding experiments. As the sulphur content of T15 was relatively high, which changed the direction of Marangoni force, the molten pool showed an obvious inward flow pattern. Results show that high temperature fluids are driven downward and consequently a deep fusion penetration is achieved. The consistence of charactistic parameters including cladding height, depth and dilution between experiment and simulation results under different process parameters indicate that the model is operative in investigating the laser cladding process.
During the laser cladding process, the transport phenomenon in the molten pool are complex including intense energy input, mass addition, strong fluid flow, rapid solidification, melting and species transport. In order to simulate the process of depositing T15 powders on 42 CrMo base steel through laser cladding, a multiphase species transport model was developed in which CLSVOF method was adopted to capture the gas-liquid interface and source terms were precisely added under the interface serving as the energy input and mass addition. The model was validated by several characteristic parameters of cladding layers obtained by single track cladding experiments. As the sulphur content of T15 was relatively high, which changed the direction of Marangoni force, the molten pool showed an obvious inward flow pattern. Results show that high temperature fluids are driven downward and consequently a deep fusion penetration is achieved. The consistence of charactistic parameters including cladding height, depth and dilution between experiment and simulation results under different process parameters indicate that the model is operative in investigating the laser cladding process.
引文
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[17]SAHOO P,DEBROY T,MCNALLAN M J.Surface tension of binary metal-surface active solute systems under conditions relevant to welding metallurgy[J].Metallurgical transactions B,1988,19(3):483-491.
[18]HOLTZER M,RETEL K.Effect of temperature and sulphur content on the surface tension of Fe-C(3.9%)-Si(1.6%)alloy[J].Canadian metallurgical quarterly,2000,39(3):339-344.
[2]ZHONG M L,WEN J L.Laser surface cladding:the state of the art and challenges[J].Proceedings of the Institution of Mechanical Engineers,Part C:Journal of Mechanical Engineering Science,2010,224(5):1041-1060.
[3]THOMPSONS S M,BLAN L K,SHAMSAEI N,et al.An overview of direct laser deposition for additive manufacturing;Part I:transport phenomena,modeling and diagnostics[J].Additive Manufacturing,2015,8:36-62.
[4]TUOMINEN J,NAKKI J,PAJUKOSKI H,et al.Microstructural and abrasion wear characteristics of laser-clad tool steel coatings[J].Surface Engineering,2016,32(12):923-933.
[5]KIDESS A,KENJERES S,KLEIJN C R.The influence of surfactants on thermocapillary flow instabilities in low Prandtl melting pools[J].Physics of Fluids,2016,28(6):062106.
[6]MILLS K C,KEENE B J,BROOKS R F,et al.Marangoni effects in welding[J].Philosophical Transactions-Royal Society of London Series A Mathematical Physical and Engineering Sciences,1998,15:911-926.
[7]WEI S P,WANG G,SHIN Y C,et al.Comprehensive modeling of transport phenomena in laser hot-wire deposition process[J].International Journal of Heat and Mass Transfer,2018,125:1356-1368.
[8]RAGHAVAN A,WEI H L,PALMER T A,et al.Heat transfer and fluid flow in additive manufacturing[J].Journal of Laser Applications,2013,25(5):052006.
[9]GAN Z T,YU G,HE X L,et al.Numerical simulation of thermal behavior and multicomponent mass transfer in direct laser deposition of Co-base alloy on steel[J].International Journal of Heat and Mass Transfer,2017,104:28-38.
[10]GAN Z T,YU G,HE X L,et al.Surface-active element transport and its effect on liquid metal flow in laser-assisted additive manufacturing[J].International Communications in Heat and Mass Transfer,2017,86:206-214.
[11]LEE Y,FARSON D F.Simulation of transport phenomena and melt pool shape for multiple layer additive manufacturing[J].Journal of Laser Applications,2016,28(1):012006.
[12]QI H,MAZUMDER J,KI H.Numerical simulation of heat transfer and fluid flow in coaxial laser cladding process for direct metal deposition[J].Journal of applied physics,2006,100(2):024903.
[13]XIE J,KAR A,ROTHENFLUE J A,et al.Temperature-dependent absorptivity and cutting capability of CO2,Nd:YAGand chemical oxygen-iodine lasers[J].Journal of Laser Applications,1997,9(2):77-85.
[14]BORIN D,ODENBACH S.Viscosity of liquid metal suspensions-experimental approaches and open issues[J].The European Physical Journal Special Topics,2013,220(1):101-110.
[15]DE A,DEBROY T.A smart model to estimate effective thermal conductivity and viscosity in the weld pool[J].Journal of Applied Physics,2004,95(9):5230-3240.
[16]TAN W,BAILEY N S,SHIN Y C.Numerical modeling of transport phenomena and dendritic growth in laser spot conduction welding of 304 stainless steel[J].Journal of manufacturing science and engineering,2012,134(4):041010.
[17]SAHOO P,DEBROY T,MCNALLAN M J.Surface tension of binary metal-surface active solute systems under conditions relevant to welding metallurgy[J].Metallurgical transactions B,1988,19(3):483-491.
[18]HOLTZER M,RETEL K.Effect of temperature and sulphur content on the surface tension of Fe-C(3.9%)-Si(1.6%)alloy[J].Canadian metallurgical quarterly,2000,39(3):339-344.
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