Article
Thermodynamics
Boxue Song, Tianbiao Yu, Xingyu Jiang, Wenchao Xi, Xiaoli Lin
Summary: A new numerical simulation method was proposed and verified to analyze the thermal history and formation of the molten pool, convective pattern, and solidification morphology in laser cladding. The results showed rapid attainment of steady-state in the molten pool, with columnar growth at the bottom, equiaxed crystals at the top, and a transition from columnar to equiaxed crystals occurring in the center.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2021)
Article
Optics
Boxue Song, Tianbiao Yu, Xingyu Jiang, Liaoyuan Chen, Wenchao Xi, Chuang Guan
Summary: Non-planar laser cladding of V-grooves with different tension angles results in varying laser energy absorption, leading to changes in melt pool volume and complex convection patterns. Moreover, when the tension angle is less than 60 degrees, cavitation generation at the bottom may occur.
OPTICS AND LASER TECHNOLOGY
(2021)
Article
Optics
Chen Shen, Chonggui Li, Yajun Guo, Chuanming Liu, Xuanjun Zhang, Xiaosong Feng
Summary: This study presents a modified finite element model to simulate the temperature evolution and clad geometry of TiAlSi coatings, distinguishing thermal properties between powders and alloys for improved simulation precision. The effect of different laser power and scan speeds on cladding layer morphologies is investigated, with results showing track depth and width are directly proportional to power and inversely proportional to speed. The modified model accurately describes single-track laser cladding geometry.
OPTICS AND LASER TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Honghao Ge, Hao Fang, Caowei Zhang, Liang Wang, Qunli Zhang, Jianhua Yao
Summary: The study demonstrates that a static magnetic field can alter the convective transport of heat and mass during the laser cladding process, resulting in uneven distribution of iron concentration due to the induced Lorentz force inhibiting melt flow.
METALLURGICAL AND MATERIALS TRANSACTIONS A-PHYSICAL METALLURGY AND MATERIALS SCIENCE
(2022)
Article
Engineering, Manufacturing
Lichao Liu, Gang Wang, Ke Ren, Yuelan Di, Liping Wang, Yiming Rong, Haidou Wang
Summary: Adding rare-earth elements can modify the microstructure and mechanical properties of laser cladding layer, as well as affect the flow pattern and cross-section in multi-pass laser cladding. The surface tension increases with increasing CeO2 content, influencing the direction of molten pool flow. Adding CeO2 also increases the inclination of the molten pool, altering the geometric shape between cladding passes.
ADDITIVE MANUFACTURING
(2022)
Article
Optics
Jihui Yang, Wurikaixi Aiyiti, Houfeng Jiang, Jialu Shan, Yutao Zhang
Summary: In this study, the influence of melt pool flow on the morphology in laser cladding process was investigated by combining experiments and simulations, as well as analyzing the impact of substrate sulfur concentration on flow field. A prediction model for inclined clad layer morphology was established. The results showed that sulfur concentration significantly affected Marangoni convection in the melt pool and resulted in changes in the melt pool morphology. The model accurately predicted the width, height, and depth of the molten layer within an error range of 8% and provided theoretical guidance for studying the inclined formation mechanism and optimizing process parameters.
OPTICS AND LASER TECHNOLOGY
(2021)
Article
Thermodynamics
Wei Xu, Pin Li, Huixia Liu, Hao Wang, Xiao Wang
Summary: This study focused on the formation of molten pool during laser transmission welding, indicating that heat conduction plays a more significant role than convection, and temperature is the key factor in molten pool formation.
INTERNATIONAL COMMUNICATIONS IN HEAT AND MASS TRANSFER
(2022)
Article
Thermodynamics
Qiyu Gao, Wanli Ling, Yuqi Zhou, Xiaohong Zhan, Honglie Shen
Summary: This paper investigated the mechanism of non-uniform distribution of elements in laser cladding layers of multi-principal high-entropy alloys (HEAs). It was found that a Marangoni circulation caused the abnormal accumulation of titanium elements in the special bud-shaped area of the cladding layer.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2023)
Article
Materials Science, Multidisciplinary
Jin Peng, Jigao Liu, Xiaohong Yang, Jianya Ge, Peng Han, Xingxing Wang, Shuai Li, Yongbiao Wang
Summary: In this paper, a heat-flow coupling model of laser welding at preheating temperature was established using FLUENT 19.0 software. The analysis of keyhole wall fluctuation and melt flow behavior in the molten pool under different preheating temperatures revealed the correlation between keyhole wall fluctuation and spatters and bubbles. The study found that the preheating temperature affects the shape of the keyhole wall and the occurrence of welding spatters and keyhole collapse.
Article
Crystallography
Jin Peng, Hongqiao Xu, Xiaohong Yang, Xingxing Wang, Shuai Li, Weimin Long, Jian Zhang
Summary: This paper presents a numerical simulation of molten pool dynamics in laser deep penetration welding of aluminum alloys using FLUENT 19.0 software. The analysis focuses on the three-dimensional transient behavior of the keyhole and the flow field of molten pool at different welding speeds. The results show that the generation of welding spatters is directly related to the fluctuation of the keyhole diameter and the welding speed has an influence on the formation of welding spatters.
Article
Materials Science, Coatings & Films
Kangning Jin, Ping Chen, Pengni Feng
Summary: During laser cladding, the inputs of mass, energy, and momentum from the powder flow have a significant impact on the molten pool and microstructure evolution. In this study, a modeling framework integrating computational fluid dynamics (CFD) with a ray tracing-based powder source and cellular automata (CA) was used to investigate the effects of powder flow on the molten pool and microstructure. Experimental verification demonstrated the accuracy of the model. The results showed that powder flow impacted the vortices in the molten pool, leading to changes in height and depth of the cladding layer and the nucleation behavior.
SURFACE & COATINGS TECHNOLOGY
(2023)
Article
Physics, Applied
Amin Ebrahimi, Chris R. Kleijn, Ian M. Richardson
Summary: The study shows that adjusting the absorbed energy flux affects the oscillatory fluid flow behavior in the melt pool, and consequently the predicted melt-pool shape and size. Additionally, changing the thermo-physical material properties artificially or using a non-deformable surface assumption lead to significant differences in melt pool oscillatory behavior.
JOURNAL OF PHYSICS D-APPLIED PHYSICS
(2021)
Article
Thermodynamics
Junyong Shen, Xiaohui Zhang
Summary: By using the lattice Boltzmann method, a double distribution LB model based on the variation of thermal conductivity and thermal diffusivity with temperature is developed to study the interaction between annular laser and material. The model is verified and shows good agreement. Both the inner and outer annular radii can regulate convective heat transfer and affect the flow pattern and depth of the molten pool. The temperature field, velocity vector field, and average Nusselt number are analyzed, and the ratio of Marangoni number to Rayleigh number is proposed for comparative analysis. It is found that smaller inner and outer annular radii result in smaller average Nusselt number and deeper molten pool.
APPLIED THERMAL ENGINEERING
(2022)
Article
Optics
Xigui Xie, Jianxi Zhou, Jiangqi Long
Summary: A 3D transient numerical model was developed to study the molten pool behavior and transmission mechanism during laser welding of dissimilar metals. The stability of the keyhole depends on the dynamic balance between the recoil pressure and the surface tension, and welding parameters significantly affect the transition layer thickness and element distribution.
OPTICS AND LASER TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Yabao Hu, Hanning Chen, Xiaodan Liang, Jichang Xie
Summary: A new approach is presented in this paper to link the integrated area of the spectral curve with the molten pool temperature, the grain size, and molten pool plasma during laser additive manufacturing. Thermal radiation theory and rapid solidification theory were applied to calculate the molten pool temperature and grain size based on spectral information. The results show that the molten pool temperature and grain size are closely related to the integrated area of the spectral curve, while electron temperature and electron density also increase with the integrated area of the spectral curve.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Thermodynamics
Boxue Song, Tianbiao Yu, Xingyu Jiang, Wenchao Xi, Xiaoli Lin
Summary: A new numerical simulation method was proposed and verified to analyze the thermal history and formation of the molten pool, convective pattern, and solidification morphology in laser cladding. The results showed rapid attainment of steady-state in the molten pool, with columnar growth at the bottom, equiaxed crystals at the top, and a transition from columnar to equiaxed crystals occurring in the center.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2021)
Article
Materials Science, Coatings & Films
Liaoyuan Chen, Tianbiao Yu, Pengfei Xu, Bo Zhang
Summary: In-situ NbC reinforced Fe-based coating was successfully fabricated on carbon steel surface by laser cladding, exhibiting excellent hardness and wear performance due to the reinforced phases and matrix composition.
SURFACE & COATINGS TECHNOLOGY
(2021)
Article
Materials Science, Ceramics
Sheng Qu, Zixuan Wang, Chao Zhang, Zhelun Ma, Tianqi Zhang, Hao Chen, Zhao Wang, Tianbiao Yu, Ji Zhao
Summary: In this study, the obliquely axial UVAP method is introduced, focusing on the fixed point MRP analysis. Theoretical calculations and modeling were conducted to understand the material removal profile and the effects of polishing parameters, such as ultrasonic amplitude and oblique angle, on the polishing efficiency. Experimental results showed good agreement with the proposed numerical model, indicating the potential of improving material removal capability in UVAP through optimizing process parameters.
CERAMICS INTERNATIONAL
(2021)
Article
Materials Science, Ceramics
Xin Chen, Yingdong Liang, Zhengyu Sun, Yu Zhao, Zhelun Ma, Liaoyuan Chen, Tianbiao Yu, Ji Zhao
Summary: The study investigated the grinding performance of TiC-Steel cermet using a customized vitrified bond cBN wheel. Results showed that the main removal modes of TiC-Steel cermet are plastic removal of steel phase and brittle fracture of ceramic phase. Surface roughness parameters increase with grinding depths and decrease with spindle rotation speed, with feed rate having less impact on surface quality. Optimal processing parameters were determined to achieve the best surface quality and lowest grinding force.
CERAMICS INTERNATIONAL
(2021)
Article
Automation & Control Systems
Liaoyuan Chen, Yu Zhao, Chuang Guan, Tianbiao Yu
Summary: Adding CeO2 to ceramics reinforced Fe-based coatings can effectively reduce deposition defects, improve microstructure uniformity, microhardness, and wear resistance. The addition of CeO2 reduces cracks and porosities, enhances the bonding performance between the coating and substrate, promotes melting of ceramic particles, and refines the microstructure. The optimum addition of 2.5 wt.% CeO2 results in the highest and most uniform microhardness and smoother worn surface, despite a higher friction coefficient.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Yingdong Liang, Chao Zhang, Xin Chen, Tianqi Zhang, Tianbiao Yu, Ji Zhao
Summary: This paper investigates the material removal mechanism of ultrasonic vibration-assisted polishing of optical glass and establishes a related model. By analyzing the effects of different parameters on the material removal rate, the prediction of material removal profile is achieved, providing a theoretical basis for deterministic material removal and polishing of complex curved surfaces.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Optics
Liaoyuan Chen, Yu Zhao, Boxue Song, Tianbiao Yu, Zhe Liu
Summary: An improved 3D multi-physics finite element model has been proposed to accurately predict the three-dimensional characteristics of coating and dynamic solidification during coaxial powder-fed laser cladding. The model shows good universality and predicting abilities for the 3D geometry of the coating. The accuracy of the model can be improved by considering powder temperature-rise and shielding gas pressure.
OPTICS AND LASER TECHNOLOGY
(2021)
Article
Optics
Yu Zhao, Huagang Liu, Tianbiao Yu, Minghui Hong
Summary: This paper explores the application of femtosecond laser-manufactured diamond tools in microtexture processing, achieving different micro-cutting effects by controlling laser ablation parameters. These microarray diamond tools demonstrate higher flexibility and efficiency in microtexture processing.
OPTICS AND LASER TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Xuewei Zhang, Tianbiao Yu, Pengfei Xu, Ji Zhao
Summary: An improved integrated estimation method based on LSTM network and PF algorithm is proposed in this study to predict tool wear values and progress, leading to the modification of cutting force model. Experimental validation shows that the proposed method enhances the availability and sustainability of micro cutting tools, with a 3.4% increase in prediction accuracy compared to not considering the influence of tool wear.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2022)
Article
Optics
Boxue Song, Tianbiao Yu, Xingyu Jiang, Liaoyuan Chen, Wenchao Xi, Chuang Guan
Summary: Non-planar laser cladding of V-grooves with different tension angles results in varying laser energy absorption, leading to changes in melt pool volume and complex convection patterns. Moreover, when the tension angle is less than 60 degrees, cavitation generation at the bottom may occur.
OPTICS AND LASER TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Wenchao Xi, Boxue Song, Jinlong Dong, Tianqi Zhang, Tianbiao Yu, Jun Wang
Summary: Laser cladding is used for repairing damaged parts of machine tools due to its advantages, but sometimes the mechanical properties of the coating do not meet process requirements. This study prepared coatings with high microhardness and flexural strength by mixing YCF102 alloy powder with different Co contents. The results showed that an increase in Co content did not result in a monotonic change in microhardness, but significantly improved flexural strength. A Co content of 8 wt% in the mixed powder led to a coating with high microhardness and flexural strength, providing a theoretical and practical basis for future research in laser cladding for machine tool repairs.
RAPID PROTOTYPING JOURNAL
(2022)
Article
Engineering, Mechanical
Liaoyuan Chen, Tianbiao Yu, Ying Chen, Wanshan Wang
Summary: This study improves the dimensional accuracy of inclined thin-walled parts fabricated by laser direct metal deposition under an open-loop control system through an adaptive slicing method and feedback adjustment of deposition height. Optimizing the defocus amount enables the matching of deposition thickness and adaptive slicing height, resulting in improved dimensional accuracy and a negative feedback of the thin-wall part height.
RAPID PROTOTYPING JOURNAL
(2022)
Article
Computer Science, Interdisciplinary Applications
Xuewei Zhang, Tianbiao Yu, Pengfei Xu, Ji Zhao
Summary: An intelligent system for evaluating sustainability performance of micro milling process is proposed in this paper, using PCA and BP algorithms. By integrating various algorithms and networks, the tool life of micro cutting tools can be predicted more accurately, optimizing the sustainability of the micro milling process.
ROBOTICS AND COMPUTER-INTEGRATED MANUFACTURING
(2022)
Article
Engineering, Manufacturing
Boxue Song, Tianbiao Yu, Xingyu Jiang, Wenchao Xi, Xiaoli Lin, Zhelun Ma, Zhao Wang
Summary: This study developed and validated a numerical model of multilayer directed energy deposition based on the single-layer directed energy deposition, with the aim of revealing the cladding forming process and solidification structure in this process. The simulation results showed the complex Marangoni convection pattern generated by the surface tension gradient in the melt pool. Additionally, the study found that multilayer directed energy deposition enhanced the penetration effect of the melt pool and resulted in a cross-layer mass transfer different from single-layer directed energy deposition. The study also analyzed the evolution of the multilayer cladding and the shift of its growth orientation, and predicted the relationship between cladding grain size and solidification properties.
ADDITIVE MANUFACTURING
(2022)
Article
Environmental Sciences
Boxue Song, Xingyu Jiang, Song Wang, Qing Liu, Tianbiao Yu
Summary: Low parts utilization, high resource consumption, and low profit margins are hindering the development of machine tool remanufacturing in China. A case study was conducted on a machine tool manufacturing company to improve the remanufacturing production line, which included remaining life assessment, additive manufacturing, quality monitoring, and reassembly quality control. The new production line reduced energy consumption and water consumption of each remanufactured machine tool and decreased pollutants generated. Despite satisfactory results, machine remanufacturing still faces difficulties in China. Suggestions for promoting remanufacturing in Chinese manufacturing companies were provided based on the case study.
ENVIRONMENTAL SCIENCE AND POLLUTION RESEARCH
(2023)
