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Research on Powder Convergence Characteristics of Powder Feeding Nozzle in Wide-Band Laser Cladding
Erhao Zhou1, Jianjun Peng1,2, Bingjing Guo1
1School of Mechanical and Electrical Engineering, Henan University of Science and Technology, Luoyang 471003, China.
Micromachines
|May 27, 2026
Summary
Optimizing laser cladding efficiency requires understanding powder feeding. This study reveals carrier gas flow controls focal length and powder concentration, while feed rate impacts focal plane concentration, enhancing powder utilization.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Powder Metallurgy
Background:
- Laser cladding efficiency is frequently hindered by suboptimal powder utilization.
- Controlling powder feeding parameters is crucial for improving the process.
Purpose of the Study:
- To investigate how powder feeding parameters influence powder stream convergence in laser cladding.
- To optimize these parameters for enhanced powder utilization and processing efficiency.
Main Methods:
- Development of a 3D wide-band symmetrical nozzle model.
- Simulation of gas-solid flow using Computational Fluid Dynamics-Discrete Element Method (CFD-DEM) coupling.
- Validation of the model through single-factor tests and experimental data.
Main Results:
- Carrier gas flow was identified as the primary parameter influencing focal length and powder concentration.
- Powder feed rate was found to be the key factor governing concentration at the focal plane.
- The CFD-DEM model demonstrated reliability in simulating gas-solid flow dynamics.
Conclusions:
- The study provides a theoretical basis for optimizing laser cladding parameters.
- Understanding the interplay between carrier gas flow and powder feed rate is essential for maximizing powder utilization.
- Optimized parameters can significantly improve the efficiency of laser cladding processes.
