激光束空域形态对激光定向能量沉积<strong>316L</strong>不锈钢热输运影响的数值模拟

doi:10.11900/0412.1961.2022.00509

金属学报

2024, Vol. 60

Issue (12): 1678-1690 DOI: 10.11900/0412.1961.2022.00509

研究论文

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激光束空域形态对激光定向能量沉积316L不锈钢热输运影响的数值模拟

任松¹, 吴家柱¹(

), 张屹², 张大斌¹, 曹阳¹, 尹存宏¹

1 贵州大学机械工程学院贵阳 550025
2 湖南大学机械与运载工程学院长沙 410082

Numerical Simulation on Effects of Spatial Laser Beam Profiles on Heat Transport During Laser Directed Energy Deposition of 316L Stainless Steel

REN Song¹, WU Jiazhu¹(

), ZHANG Yi², ZHANG Dabin¹, CAO Yang¹, YIN Cunhong¹

1 School of Mechanical Engineering, Guizhou University, Guiyang 550025, China
2 College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, China

引用本文:

任松, 吴家柱, 张屹, 张大斌, 曹阳, 尹存宏. 激光束空域形态对激光定向能量沉积316L不锈钢热输运影响的数值模拟[J]. 金属学报, 2024, 60(12): 1678-1690.
Song REN, Jiazhu WU, Yi ZHANG, Dabin ZHANG, Yang CAO, Cunhong YIN. Numerical Simulation on Effects of Spatial Laser Beam Profiles on Heat Transport During Laser Directed Energy Deposition of 316L Stainless Steel[J]. Acta Metall Sin, 2024, 60(12): 1678-1690.

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摘要:

激光整形是调控微观结构以改善增材制件性能的重要手段，但是激光整形定向能量沉积过程中的基本热输运行为仍需阐明。本工作建立了激光定向能量沉积三维热输运模型，对比研究了Gaussian形态(GP)、超Gaussian形态(SGP1、SGP2)和完全平顶形态(FTP) 4种激光束空域形态对316L不锈钢熔池传热和流体流动特征的影响。结果表明：GP、SGP1、SGP2和FTP下熔池的峰值温度依次降低，凝固界面上的温度梯度从熔池顶部到熔池底部逐渐上升；凝固界面的温度梯度与其到熔池表面光束中心的距离负相关，与凝固界面的法方向和激光扫描方向的夹角正相关；在GP、SGP1、SGP2和FTP作用下，靠近熔池后部的相同凝固界面处的温度梯度依次增大，但熔池底部的温度梯度却依次减小，熔池的平均流速依次减小；4种激光束空域形态下的熔池流动由Marangoni剪切应力主导，传热由Marangoni对流传热和热传导共同主导。

关键词 ：激光定向能量沉积, 空域形态, 316L不锈钢, 热输运, 数值模拟

Abstract：

The distribution characteristics and magnitude of energy density on the cross section of a laser beam are determined by its spatial profile, which directly impacts heat transport during laser material processing. Hence, it is essential to understand the influence of spatial profiles on heat transport during laser directed energy deposition with synchronous material delivery. Herein, a three-dimensional heat transport model that takes into account important physical events such as laser-powder-pool coupling, thermal-fluid coupling, solid-liquid phase change, and multiple heat transfer was established. The model was validated using single-track single-layer deposition experiments. The effects of four spatial laser beam profiles, including Gaussian (GP), super-Gaussian (SGP1 and SGP2), and pure flat-topped (FTP) profiles, on the heat transport and fluid flow within the molten pool were investigated. Simulated results show that peak temperatures of the molten pool decrease sequentially under GP, SGP1, SGP2 and FTP, and the temperature gradients on the solidification interface increase gradually from the top to the bottom of the molten pool. Temperature gradients on the solidification interface positively correlate with the angle between the normal direction of the solidification interface and the laser scanning direction, and negatively correlate with the distances from the beam center on the molten pool surface. Under all four spatial laser beam profiles, temperature gradients at the same positions on the solidification interface near the rear of the molten pool increase, while those at the bottom of the molten pool decrease. The molten pool exhibits an outward annular flow pattern under all four spatial laser beam profiles with fluid flows mainly driven by Marangoni shear stress. Heat transfer within the molten pool is dominated by Marangoni convection and heat conduction. Average fluid velocities within the molten pool decrease successively according to the following order: Gaussian, super-Gaussian, and pure flat-topped profiles.

Key words： laser directed energy deposition spatial profile 316L stainless steel heat transport numerical simulation

收稿日期: 2022-10-12

ZTFLH:

TG142.3

基金资助:国家自然科学基金项目(51975205);贵州省科学技术基金项目([2021]265);贵州省科学技术基金项目([2023]017);贵州大学自然科学基金项目((2021)15);贵州大学研究生创新人才计划项目(202203)

通讯作者: 吴家柱，wujz_pillar@163.com，主要从事高性能激光制造研究

Corresponding author: WU Jiazhu, associate professor, Tel: (0851)83627516, E-mail: wujz_pillar@163.com

作者简介: 任松，男，1999年生，硕士生

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链接本文:

https://www.ams.org.cn/CN/10.11900/0412.1961.2022.00509 或 https://www.ams.org.cn/CN/Y2024/V60/I12/1678

图1 激光定向能量沉积原理的示意图

图2 不同空域形态因子(K)下的激光束空间密度分布示意图

图3 同轴粉末束的坐标系示意图

图4 数值模型的网格划分

Physical parameter	Value	Unit	Ref.
Solidus temperature T_sol	1648	K
Liquidus temperature T_liq	1673	K
Solid specific heat c_sol	604	J·kg^-1·K^-1
Liquid specific heat c_liq	824	J·kg^-1·K^-1
Solid thermal conductivity k_sol	25	W·m^-1·K^-1
Liquid thermal conductivity k_liq	36	W·m^-1·K^-1
Room temperature T_ref	293.15	K
Solid density ρ_sol	8000	kg·m^-3
Liquid density ρ_liq	6893	kg·m^-3
Emissivity $ε$	0.7		[26]
Laser absorptivity $η$	0.38
Latent heat of fusion L	2.5 × 10⁵	J·kg^-1	[29]
Convective heat transfer coefficient h_con	80	W·m^-2·K^-1	[30]
Thermal expansion coefficients α_exp	5.85 × 10^-5	K^-1	[31]
Dynamic viscosity μ	6 × 10^-3	kg·m^-1·s^-1	[32]
Permittivity of vacuum σ'	5.67 × 10^-8	W·m^-2·K^-4

表1 传热模型的参数值

Physical module	Boundary
	Top surface	Other sectional surface
	Top surface	Other sectional surface
Heat transfer	$T r e f = 293.15 K$	$T r e f = 293.15 K$
Fluid flow	$u 0 = 0$	$u 0 = 0$
	$P 0 = 0$	$P 0 = 0$
Moving mesh	$V L / G 0 = 0$	$d x, d y, d z = 0$

表2 模拟中的初始值

图5 定向能量沉积实验平台

表3 沉积工艺参数

图6 超Gaussian形态(SGP1，K = 4.2)作用下不同功率时沉积道形貌的数值模拟结果与实验结果

表4 超Gaussian形态(SGP1，K = 4.2)作用下不同功率时的熔池形貌特征参数

图7 4种激光束空域形态下熔池的温度场

图8 4种激光束空域形态下图4中轨迹1的温度分布

图9 Gaussian形态(GP)下熔池纵向切片的温度梯度

图10 GP下2个纵向切面上的温度梯度分布

图11 4种激光束空域形态作用下2个切面凝固界线上考察点的温度梯度

图12 4种激光束空域形态作用下切面凝固界线上考察点到熔池表面光束中心的距离

图13 4种激光束空域形态作用下激光扫描方向与切面凝固界线上考察点处法线方向的夹角

图14 4种激光束空域形态下熔池的速度场

图15 4种激光束空域形态下图4中轨迹1的流速分布

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