Mid Term Paper ME 206

CFD MODELING OF PARTICLE
FLOW IN NOZZLE FOR ADDITIVE

MANUFACTURING
(CFD) is the process of mathematically modeling a
physical phenomenon involving fluid flow and
solving it numerically using computational
prowess.Directed energy deposition (DED) uses a
high-intensity laser beam as a heat source, which
melts the fed material in the form of powder or
wire and deposits it on the substrate. Out of the
many applications of CFD analysis, modeling of
flow passing through a nozzle is a widespread first
application. The material flow through a nozzle
gets distributed unsymmetrically when the nozzle
GROUP 5 is held at some angle of inclination.The objective
Desai Utsav Manojkumar
Bhole Dhananjay Sanjay of this study is to investigate ways, primarily
Pragyesh Gupta
Mayur Bhavat Morey
changing the wall distance, to make the distribution
Vivek Dhara symmetric and achieve the highest Powder
Project Guide : Sachin Alya Catchment Efficiency for a given incline angle.
Introduction
The Laser Direct Energy Decomposition(DED), is the process which adds
the material along with the Laser which melts it simultaneously. In a DED
printer, the nozzle moves to the specific locations to make the required
shapes.
Here is the image of the nozzle of which the
analysis is to be done. In this nozzle, the
metal powder flows through the gap
between the walls driven by the inert gas,
specifically, Argon. The powder flow
converges to a point and there the laser
beam melts the metal and deposits on the
surface on which the additive
manufacturing is to be done. The particles
used in this process are Spherically
atomized Crucible Powder Metallurgical steel, CPM 9V, whose particle size
varies from 75 μm to 210 μm. Also the particle size is assumed to be
following the Rosin-Rammler distribution.
The following are some of the assumptions that are taken into account
while modeling this nozzle in a Computational Fluid Dynamics (CFD)
software:
1. During the process, the temperature of the particles does not vary.
2. The gas is said to be turbulent in its flow.
3. The particles' velocity as they enter is assumed to be the same as the
gas's velocity.
4. The particle size distribution is expected to follow the
Rosin-Rammler distribution, as mentioned in the preceding theory.
Process modeling and/or analysis by previous

researchers
1. Using an annular laser beam configuration and the effect of laser
beam intensity distribution, model processing was used to
investigate PCE (Powder Catchment Efficiency).
2. Powder catchment efficiencies for coaxial and off-axis nozzles
had been investigated (taking the effect of axial speed, mass
flow, and laser power)
3. The influence of tilt on powder catchment efficiency was
investigated, as well as the evolution of the clad shape.
4. The impact of the nozzle slit gap and nozzle cone angle on
powder concentration
5. A 3D model for powder flow is presented based on process
modeling and tests, and the powder flux is described at various
standoff distances.
6. A gravity-driven powder flow in a coaxial nozzle is presented
using process modeling.
7. Variation in PCE (Powder Catchment Efficiency) as a function of
substrate inclination angle. The drop in powder catchment
efficiency does not show any discernible change, but there is a
significant decrease beyond 45 degrees, up to 19 percent.
Studies Reported
Different fluids and their composition used for additive manufacturing
1. CPM 9 V - Spherical atomized Crucible Particle Metallurgical
steel
2. Cobalt Chrome - Cobalt Chromium Molybdenum alloy
3. 17-4 Stainless Steel(17-4SS)
Open issues for further investigation

It is important to note here that even in a vertical nozzle, the gas powder
flow can undergo local turbulence. Because of this turbulence in the
carrier gas, there can be deviations from the theoretical values and also
mechanical energy losses resulting in rise in temperature. This rise might
have effects on measured values of Powder Catchment Efficiency.
Also, the powder catchment

efficiency for the inclined nozzle
with updated wall distance can
be lower than when the incline
angle was 0°, i.e, the powder
catchment efficiency would be
maximum when the nozzle was
vertical. This happens because
when the nozzle is inclined at
some angle, the particle flow is
asymmetric with more particles
flowing from the lower half. The
catchment efficiency would
drastically increase because of
this. After updating the other
half of the nozzle as shown in the
figure, the powder stream area
would reduce and this would
result in increasing the PCE. But still, PCE for this arrangement would be
smaller than the zero incline case.
Problem statement for Module 2
● Study of the variation of the output particle flow from the nozzle by
varying the angle of inclination.
● Finding a way to make the flow uniform by changing the distance
between the walls of the inclined nozzle.
Proposed methodology for accomplishing the objectives

and conclusions
1. Understanding the basics of Ansys Fluent, the software widely used
for CFD analysis
2. Modeling of the Nozzle in the software
3. CFD Modeling of Flow in Inclined Nozzle in Ansys Fluent
4. CFD Modeling of Flow in the Inclined Nozzle with updated wall
distance in Ansys Fluent
References
1. Discrete Phase Modeling of the Powder Flow Dynamics and the
Catchment Efficiency in Laser Directed Energy Deposition With
Inclined Coaxial Nozzles – Sachin Alya (LINK)
2. Metal Powder Material analysis (LINK1, LINK2, LINK3)
3. Characterization of Metal Powders Used for Additive Manufacturing

(nist.gov)
4. Particle Compositions(LINK1, LINK2, LINK3)
5. Co-Cr Properties (proto3000.com)

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CFD MODELING OF PARTICLE

FLOW IN NOZZLE FOR ADDITIVE

Process modeling and/or analysis by previous

Open issues for further investigation

Also, the powder catchment

Proposed methodology for accomplishing the objectives

2. Metal Powder Material analysis (LINK1, LINK2, LINK3)

3. Characterization of Metal Powders Used for Additive Manufacturing

4. Particle Compositions(LINK1, LINK2, LINK3)

5. Co-Cr Properties (proto3000.com)

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