Influence of particle size on powder velocity distribution at the nozzle outlet in Directed Energy Deposition

IF 7.9 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design Pub Date : 2025-09-10 DOI:10.1016/j.matdes.2025.114680

Tijan Mede , Andrej Jeromen , Edvard Govekar , Michael Mallon , Matjaž Godec

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Abstract

Metal-based Directed Energy Deposition (DED) is considered one of the variations of additive manufacturing with the highest potential, particularly for space industry and in-orbital manufacturing. The technology however still faces various challenges, many of which can be traced back to poor control and understanding of the powder delivery. Velocity distribution of powder particles at the DED nozzle outlet has a key influence on the results of any predictive model of powder stream and yet remains largely disputed. Certain numerical studies highlighted a possible influence of powder particle size on the velocity condition at the nozzle exit, yet no experimental studies confirmed this effect. The experimental campaign described in this paper quantifies this relation between powder particle size and velocity distribution at the nozzle outlet and a strong decrease of particle speed with particle size is observed. Moreover, smaller particles are observed to travel at speeds higher than the mean carrier gas speed suggesting powder particle segregation within the nozzle as one of the mechanisms driving speed differences at the nozzle outlet.

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定向能沉积中粒径对喷嘴出口粉末速度分布的影响

金属基定向能沉积（DED）被认为是最有潜力的增材制造技术之一，特别是在航天工业和在轨制造领域。然而，该技术仍然面临着各种挑战，其中许多挑战可以追溯到对粉末输送的控制和理解不佳。粉末颗粒在DED喷嘴出口的速度分布对任何粉末流预测模型的结果都有关键影响，但仍然存在很大争议。一些数值研究强调了粉末粒度对喷嘴出口速度条件的可能影响，但没有实验研究证实这种影响。本文描述的实验活动量化了粉末粒度与喷嘴出口速度分布之间的关系，并观察到颗粒速度随粒径的强烈下降。此外，观察到较小颗粒的运动速度高于平均载气速度，这表明喷嘴内的粉末颗粒偏析是喷嘴出口速度差异的驱动机制之一。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Materials & Design Engineering-Mechanical Engineering

CiteScore

14.30

自引率

7.10%

发文量

1028

审稿时长

85 days

期刊介绍： Materials and Design is a multi-disciplinary journal that publishes original research reports, review articles, and express communications. The journal focuses on studying the structure and properties of inorganic and organic materials, advancements in synthesis, processing, characterization, and testing, the design of materials and engineering systems, and their applications in technology. It aims to bring together various aspects of materials science, engineering, physics, and chemistry. The journal explores themes ranging from materials to design and aims to reveal the connections between natural and artificial materials, as well as experiment and modeling. Manuscripts submitted to Materials and Design should contain elements of discovery and surprise, as they often contribute new insights into the architecture and function of matter.