Laser cladding is an advanced manufacturing technology for preparing high-performance metallurgical coatings on metal substrates that is widely used in industrial production. In order to improve the powder utilization rate and reduce the waste of powder in the coaxial powder feeding laser cladding process, the Euler–Lagrange theory was used to establish the simulation model of gas-powder two-phase flow in laser cladding. Fluent was used to simulate the powder particle size, powder particle shape factor, carrier gas flow rate, and powder feed rate under different process conditions, and the results were verified by experiments. Through analysis, under the process parameters of a carrier gas flow rate of 4 L / min and a powder feed rate of 15 g / min, the powder utilization rate was high and the surface of the cladding layer was smooth. When the particle size was 100 mesh and the particle shape factor approached 1.0, the concentration of powder focus was higher and the convergence effect was the best. The influence of powder process parameters on powder convergence was comprehensively analyzed, which is of great significance for the subsequent optimization design of nozzle and the improvement of powder utilization in the laser cladding process.
To study the change of coaxiality of rotor shaft during laser cladding, a numerical simulation of the rotor shaft was carried out by ANSYS Workbench, and the temperature field and structure field of the rotor shaft were simulated and analyzed by indirect coupling of transient temperature field and transient structure field. The temperature distribution of the rotor shaft during laser cladding was obtained from the results of the temperature field. The maximum temperature is 2350°C, and the final temperature converges to about 2100°C. Then, the results obtained from the temperature field are entered into the structure field as loads, and the change of coaxiality of rotor shaft during laser cladding is obtained. Finally, the laser is used to clad Fe60 powder on the 45 steel rotor shaft, and the coaxiality of the rotor shaft after cladding is measured by Taylor cylindricity meter. The measurement results are basically consistent with the simulation results, and the error is <10 % . It lays a good foundation for exploring the cladding mode or track that can maintain better coaxiality of rotor shaft in the process of laser cladding and is of great significance for the repair of damaged rotor shaft.
The thin-disk shape laser crystal is the core component of the thin disk laser. In the experiment, we found that the crystal edge is prone to abnormal high temperature in the operation, which causes the thin disk laser's conversion efficiency to decrease, and even the make crystal cracks. In order to solve this problem, two aspects that may cause this effect are researched during the disc crystal manufacturing process, and finally determined that the splash of solder during the packaging process is the main cause of this problem. In the end, we used the edge chamfering method to eliminate this problem, and the finally obtained thin disk crystal can reduce the temperature by 50% and increase the conversion efficiency by 15% when the laser operates.
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