Powder Flow Feed Behavior in Synchronous Induction-Assisted Laser Deposition

Synchronous induction-assisted laser deposition (SILD) is a widely used powder feeding-based additive manufacturing technology developed from directed energy deposition (DED). In SILD, the powder feed behavior is a decisive factor for the geometrical features and microstructure of the deposition. Therefore, the study about the influence mechanism of processing parameters on the powder flow feed behavior in an electromagnetic field is important for the application of SILD. In this research, the distribution of 30CrMnSiA steel powders injected in SILD was obtained via experimental observation, and the influence of the parameters on the powder flow characteristics was elucidated using electromagnetic field simulation and theoretical analysis. It was confirmed that the moving particles undergo an acceleration caused by the Lorentz force related to the distribution of the electromagnetic field, magnetic flux density, and the injection speed of the powder. The Lorentz force accelerated the particles and inclines, which diverged the powder flow. The maximum powder concentration decreases with increasing input current; first increasing and then decreasing with the increase of the carrier gas flow rate. The powder feed rate remains an indistinctive factor of the powder flow characteristics in a manner similar to traditional laser manufacturing.