Research on Powder Convergence Characteristics of Powder Feeding Nozzle in Wide-Band Laser Cladding

Laser cladding processing efficiency is often limited by low powder utilization. To address this, our study elucidates the mechanism by which powder feeding parameters influence powder stream convergence, aiming to optimize these parameters. A three-dimensional model of a wide-band symmetrical nozzle was developed using a Computational Fluid Dynamics—Discrete Element Method (CFD-DEM) coupling method to simulate the gas–solid flow. Single-factor tests and experimental validation confirmed the model’s reliability. The results identify carrier gas flow as the key parameter controlling the focal length and powder concentration, while the powder feed rate primarily governs the concentration on the focal plane. These findings provide a theoretical foundation for optimizing laser cladding parameters to enhance powder utilization.