Numerical Simulation And Experimental Study Of Metallic Part Rapid Forming Based On Single Track Laser Cladding

Laser Cladding Rapid Forming (LCRF) is a new developed technology on the basis of laser cladding and rapid forming in the recent years. In LCRF the substrate and the metallic powder fed synchronously are melt by laser beam and the metallurgical combination is formed, then the compact part with regular figures is manufactured layer by layer on the substrate. LCRF has some special advantages, such as high integration, high production efficiency, wide range of processable materials, no pollution to the environment and so on. So, LCRF has been given more and more attention.In LCRF, something is showed as follows: the first, the melt pool irradiate by the laser contains much information of the forming process, the stable and appropriate pool size is the key to the forming and to guarantee the forming precision and the biggest effect to the melt pool is the temperature field, so, the interaction between laser and substrate, powder must be analyzed firstly before researching the temperature field. The second, the formed part is accumulated by cladding coating layer by layer, so, it is important to control the geometrical parameters in LCRF for the final shape and precision. In this article the domestic and foreign research situation of mathematical model in LCRF is reviewed at first, and on the basis of which the main content are mainly researched and analyzed as follow:(1) The interaction between laser and substrate, powder is analyzed. The heat effect and the attenuation of laser beam in powder flow are calculated and so on.(2) The mathematical model of LCRF is built, and on the basis of which the real-time temperature field in LCRF is simulated with ANSYS.(3) The experiment of rapid forming with 5kW CO2 laser, powder(Ni60AA), substrate(Q235A) is performed, and the geometrical parameters of cladding are measured.(4) The area model of cross section of cladding is built according to the results of the analysis of the interaction of laser and powder and the results of the numerical simulation of temperature field, it is found that the results calculated by physical parameters and process parameters coincide well with the practical results.