A Simulation Study on the Effect of Supersonic Ultrasonic Acoustic Streaming on Solidification Dendrite Growth Behavior During Laser Cladding Based on Boundary Coupling
Abstract
:1. Introduction
2. Materials and Methodology
2.1. Material Parameterization for Laser Cladding
2.2. Governing Equation for Laser Cladding
- (1)
- The energy density of the laser heat source acting on the melt has a Gaussian distribution;
- (2)
- The fluid in the melt pool is an incompressible Newtonian fluid;
- (3)
- The melt metal flow in the melt pool is laminar;
- (4)
- The impact caused by momentum when the powder enters the melt pool is ignored;
- (5)
- The loss of heat dissipation caused by the high temperature of the melt is ignored;
- (6)
- The process of powder addition to the substrate follows a Gaussian distribution;
- (7)
- The absorption and reflection of the laser energy of the powder are linearly related to the amount of powder delivery.
2.3. Ultrasonic Vibration Theory
2.4. Acoustic Streaming Effect
2.5. Phase Field-Controlling Equations
2.6. Anisotropy of Interfacial Growth
2.7. Establishment of Quantitative Binary Alloy Phase Field Model
3. Selection for Microscopic Boundary
3.1. Temperature Field Boundary Selection
3.2. Flow Field Boundary Extraction Under Silent Flow
3.3. Flow Field Boundary Extraction Under Acoustic Flow
4. Results and Discussion
4.1. Dendrite Growth Behavior of Laser Cladding Without Flow Field
4.2. Growth Behavior of Convective Dendrites Under Silent Flow
4.3. Growth Behavior of Convective Dendrites Under Acoustic Flow
5. Conclusions
- (1)
- The numerical simulation results of coupling a static flow field and a sound flow field show that melt flow changes the heat and mass transfer behavior at the solidification interface and also changes the growth morphology of dendrites. The dendrite growth is inhibited under parallel concurrent flow, and the dendrite at the original vertical interface under shear flow inclines to the oncoming side. The dendrite tilt in the flow field is as follows: influenced by convection, the dendrite tilts to the oncoming side, and the tilt angle is small. Due to the influence of convection and the orientation of oncoming dendrites (the dendrites that are inclined to the oncoming side due to competitive growth), the dendrites are inclined to the oncoming side, and the inclination angle is large. Influenced by convection and consequent dendrite orientation (the dendrites that grow inclined to the consequent side due to competitive growth), the dendrites grow inclined to the consequent side, and the inclination angle is large.
- (2)
- Acoustic flow increases the flow velocity of the melt pool, increases the dendrite tilt angle to the onstream side, and promotes the growth of secondary dendrite arms on the onstream side. At the same time, the melt flow is more uniform, the solute distribution of dendrite growth is improved, and the enrichment and segregation of secondary elements between dendrites are reduced.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Elemental | C | Si | Mn | Cr | Ni | Cu | P | S | Fe |
---|---|---|---|---|---|---|---|---|---|
Quantity contained | 0.45 | 0.27 | 0.65 | 0.02 | 0 | 0.01 | 0.016 | 0.007 | Bal |
Elemental | C | Si | Mn | Cr | Ni | P | S | Mo | Fe |
---|---|---|---|---|---|---|---|---|---|
Quantity contained | 0.08 | 1.00 | 2.00 | 16~18 | 13 | 0.045 | 0.002 | 2~3 | Bal |
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Han, X.; Zhan, H.; Li, C.; Wang, X.; Liu, J.; Li, S.; Sun, Q.; Kong, F. A Simulation Study on the Effect of Supersonic Ultrasonic Acoustic Streaming on Solidification Dendrite Growth Behavior During Laser Cladding Based on Boundary Coupling. Coatings 2024, 14, 1381. https://doi.org/10.3390/coatings14111381
Han X, Zhan H, Li C, Wang X, Liu J, Li S, Sun Q, Kong F. A Simulation Study on the Effect of Supersonic Ultrasonic Acoustic Streaming on Solidification Dendrite Growth Behavior During Laser Cladding Based on Boundary Coupling. Coatings. 2024; 14(11):1381. https://doi.org/10.3390/coatings14111381
Chicago/Turabian StyleHan, Xing, Hao Zhan, Chang Li, Xuan Wang, Jiabo Liu, Shuchao Li, Qian Sun, and Fanhong Kong. 2024. "A Simulation Study on the Effect of Supersonic Ultrasonic Acoustic Streaming on Solidification Dendrite Growth Behavior During Laser Cladding Based on Boundary Coupling" Coatings 14, no. 11: 1381. https://doi.org/10.3390/coatings14111381