CFD–DEM simulation of powder flow in a continuous coaxial nozzle for laser metal deposition

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dc.contributor.authorPedrolli, Lorenzo
dc.contributor.authorAchiaga, Beatriz
dc.contributor.authorLópez, Alejandro
dc.date.accessioned2026-09-11T14:36:16Z
dc.date.available2026-09-11T14:36:16Z
dc.date.issued2026-10-01
dc.date.updated2026-09-11T14:36:16Z
dc.description.abstractThis work presents a fully coupled Computational Fluid Dynamics and Discrete Element Method (CFD–DEM) simulation of powder transport in continuous coaxial Laser Metal Deposition (LMD) nozzles, implemented in Simcenter STAR-CCM+. The methodology integrates a Johnson–Kendall–Roberts (JKR) adhesive contact model via custom field functions to represent cohesive particle–wall interactions influencing residence times and temporal flow structure. A refined polyhedral mesh resolves internal channels and external jet regions while maintaining coupling stability, with physics including two-species gas mixing (argon/air), Gidaspow drag, Sommerfeld shear lift, and gravity. Validation at a representative operating point (3 L/min carrier gas, 15 L/min shielding flow, Rosin–Rammler size distribution, 4.5 g/min feed) yields spatial footprints, centerline peak acceleration of ∼50 m/s2, and a 19% exit mass-flow irregularity (2 ms moving average). The predicted mass-flow irregularity (19% vs. 16% experimental) and accelerations agree closely with measurements, confirming rebound-driven intermittency and azimuthal redistribution at distributor fins as the dominant unsteadiness sources. Conversely, the standoff underprediction (10.2 mm vs. 16 mm) is traced to unresolved exit gas expansion under the incompressible assumption and drag calibration for the particle-laden jet, defining concrete refinement priorities for predictive simulation.en
dc.identifier.citationPedrolli, L., Achiaga, B., & Lopez, A. (2026). CFD–DEM simulation of powder flow in a continuous coaxial nozzle for laser metal deposition. Advanced Powder Technology, 37(10). https://doi.org/10.1016/J.APT.2026.105403
dc.identifier.doi10.1016/J.APT.2026.105403
dc.identifier.eissn1568-5527
dc.identifier.issn0921-8831
dc.identifier.urihttps://hdl.handle.net/20.500.14454/6636
dc.language.isoeng
dc.publisherElsevier B.V.
dc.rights© 2026 The Society of Powder Technology, Japan
dc.subject.otherCFD–DEM
dc.subject.otherContinuous coaxial nozzle
dc.subject.otherLaser metal deposition
dc.subject.otherMultiphase flow
dc.subject.otherPowder stream stability
dc.titleCFD–DEM simulation of powder flow in a continuous coaxial nozzle for laser metal depositionen
dc.typejournal article
dcterms.accessRightsopen access
oaire.citation.issue10
oaire.citation.titleAdvanced Powder Technology
oaire.citation.volume37
oaire.licenseConditionhttps://creativecommons.org/licenses/by/4.0/
oaire.versionVoR
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