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Keywords = rectangular powder nozzle

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18 pages, 4264 KB  
Article
Numerical Simulation and Modeling of Powder Flow for Rectangular Symmetrical Nozzles in Laser Direct Energy Deposition
by Bin Hu, Junhua Wang and Li Zhang
Coatings 2025, 15(7), 744; https://doi.org/10.3390/coatings15070744 - 23 Jun 2025
Viewed by 1027
Abstract
Wide-beam laser direct energy deposition (LDED) has been widely used due to its superior deposition efficiency. To achieve optimal laser-powder coupling, this technique typically employs rectangular powder nozzles. This study establishes a simulation model to systematically investigate the powder flow field characteristics of [...] Read more.
Wide-beam laser direct energy deposition (LDED) has been widely used due to its superior deposition efficiency. To achieve optimal laser-powder coupling, this technique typically employs rectangular powder nozzles. This study establishes a simulation model to systematically investigate the powder flow field characteristics of rectangular symmetric nozzles. Through parametric analysis of powder feeding rate, carrier gas flow rate, and shielding gas flow rate, the effects on powder stream convergence behavior are quantitatively evaluated to maximize powder utilization efficiency. Key findings reveal that, while the powder focal plane position is predominantly determined by nozzle geometry, powder feeding parameters exhibit negligible influence on flow field intersections. The resulting powder spot demonstrates a rectangular profile slightly exceeding the laser spot dimensions, and the powder concentration exhibits a distinctive flat-top distribution along the laser’s slow axis, contrasting with a Gaussian distribution along the scanning direction. Experimental validation through powder collection tests confirms strong agreement with the simulation results. Furthermore, a mathematical model was developed to accurately describe the powder concentration distribution at the focal plane. These findings provide fundamental theoretical guidance for optimizing powder feeding systems in wide-beam LDED applications. Full article
(This article belongs to the Special Issue Laser Surface Engineering and Additive Manufacturing)
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12 pages, 4045 KB  
Article
Improving the Efficiency of Air Plasma Spraying of Titanium Nitride Powder
by Aidar Kengesbekov, Bauyrzhan Rakhadilov, Zhuldyz Sagdoldina, Dastan Buitkenov, Yelmurat Dosymov and Manarbek Kylyshkanov
Coatings 2022, 12(11), 1644; https://doi.org/10.3390/coatings12111644 - 30 Oct 2022
Cited by 17 | Viewed by 2465
Abstract
The operation modes of a plasmatron for powder coating spraying have been studied. The plasmatron has a node of annular input and a gasdynamic focusing of the powder, and the outlet holes of the nozzle-anode are made in the form of rectangular narrowing-expanding [...] Read more.
The operation modes of a plasmatron for powder coating spraying have been studied. The plasmatron has a node of annular input and a gasdynamic focusing of the powder, and the outlet holes of the nozzle-anode are made in the form of rectangular narrowing-expanding channels (No.34334 RK: IPC H05H 1/42). The dynamics and trajectories of the powder particles in the plasmatron were investigated. The paper analyzes the influence of plasmatron arc current and working gas flow rate on the structure and properties of the obtained coatings. It is established that the phase composition of the sprayed coatings and the initial powder is the same: the main phase is the compound TiN, in addition, the structure contains the phase TiO2. The results of tribological tests of the coatings under dry friction conditions according to the ball-on-disk scheme are presented. Within the framework of this study, it can be said, from the point of view of obtaining denser coatings with high performance characteristics, that the optimal modes of plasma spraying of TiN powder are a current of 250 A and the working gas flow rate of argon 34 L/min. Full article
(This article belongs to the Special Issue Surface Engineering and Tribology)
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