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SUNY Establishes Powder Capture Efficiency Prediction Framework for Wire-Powder Coaxial DED
2026-06-23
A research team at the State University of New York has developed a powder capture efficiency (PCE) prediction framework for coaxial wire-powder directed energy deposition (CWP-DED). The process uses six symmetric diode lasers围绕 vertically fed SS316L wire, with three inclined coaxial powder nozzles delivering SiC particles. A physics-based analytical model was established through Monte Carlo particle injection coupled with Lagrangian transport, and melt pool geometry was quantified via high-speed imaging. Simulations show PCE of 54-57% under moderate conditions, dropping to 39% at high powder loads due to restricted melt pool spreading and enhanced shielding effects. The framework provides a quantitative tool for predictive control of powder utilization, process efficiency, and compositional uniformity in CWP-DED metal matrix composite manufacturing.
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纽约州立大学建立丝-粉同轴DED粉末捕获效率预测框架
美国纽约州立大学研究团队建立了面向同轴丝-粉定向能量沉积（CWP-DED）的粉末捕获效率（PCE）预测框架。工艺采用六束对称二极管激光器围绕垂直送进的SS316L丝材，三个倾斜同轴粉末喷嘴输送SiC颗粒。通过蒙特卡洛粒子注入与拉格朗日输运耦合建立基于物理的分析模型，熔池几何通过高速成像量化。模拟表明，中等工况下PCE为54-57%，高粉末负载时因熔池铺展受限和屏蔽效应增强降至39%。该框架为CWP-DED金属基复合材料制造中粉末利用率、工艺效率和成分均匀性的预测控制提供了定量工具。