Numerical simulation and experimental validation of powder flux distribution in coaxial laser cladding

In this research work a numerical model which simulates the powder flux distribution on a coaxial nozzle is presented. CFD fluent code was used to solve the model equations. The geometry of the domain was obtained using a reverse engineering process of a coaxial nozzle. The model required a deep study of the powder size distribution and feed rate because of their importance as input parameters. The simulation for the discrete phase model was carried out using both, the turbulence k–ɛ model and the Euler–Lagrange approximation. During the model validation a technique based on the selective weight measuring on planes perpendicular to the nozzle axis was used. The powder flux model validation results showed coherence between the estimated and measured particle flux values, particularly when the powder stream presents a Gaussian profile. A simple geometrical model was presented as an application example of the flux distribution model to estimate the clad height.