Numerical modeling of powder stream in extreme high-speed linear laser material deposition

A new structure of side powder feeding nozzles for extreme high-speed linear laser material deposition was designed. In this structure, the spatial concentration distribution of powder flow is controlled by multi-channel cylindrical beam splitting and conical rectifier. The turbulent and discrete phase models were used to study the flow field and powder distribution under the conditions of specific carrier gas flow rate and powder size. The results show that the powder feeding shaping structure can realize the powder flow linear and uniform distribution. Besides, it is proved that the prepared cladding layer has good surface quality through the experimental investigation.