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<p>The homogeneous SiC distribution is desired but it is difficult to achieve during fabricating SiC particle reinforced Al matrix composites of brake disc. This work presents a three-dimensional thermo-fluid model to simulate dual-wire laser directed energy deposition for brake disc manufacturing. The model adopts a multiphase interface tracking method to describe the behaviors of air, aluminum droplets and SiC droplets. The developed model bridges the gap from process to forming, which allows for the prediction of the temperature field, fluid flow, tracking particles and SiC distribution in both the molten pool and final deposition. The results indicated that adopting a larger SiC wire diameter intensifies fluid flow in the molten pool, thereby promoting homogeneous distribution of SiC particles. Increasing the wire feeding rate aggravates molten pool instability, and welding spatter emerges when the rate reaches 0.06&#xa0;m/s. If the dual-wire gap is smaller than 2.0&#xa0;mm, the two droplets merge, which leads to defective deposited morphology. The provided analyses of heat and fluid flow and the predictions of deposition morphology are helpful for the design of process parameters.</p>

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Dual-wire numerical model to predict molten pool and SiC distribution for brake disc laser-directed energy deposition

  • 期刊论文

  • 发表日期：

    2026年7月27日

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  • Wenmin Ou,
  • Gaoyang Mi,
  • Guolin Guo,
  • Yaocheng Zhang,
  • Xueyong Yu

摘要

The homogeneous SiC distribution is desired but it is difficult to achieve during fabricating SiC particle reinforced Al matrix composites of brake disc. This work presents a three-dimensional thermo-fluid model to simulate dual-wire laser directed energy deposition for brake disc manufacturing. The model adopts a multiphase interface tracking method to describe the behaviors of air, aluminum droplets and SiC droplets. The developed model bridges the gap from process to forming, which allows for the prediction of the temperature field, fluid flow, tracking particles and SiC distribution in both the molten pool and final deposition. The results indicated that adopting a larger SiC wire diameter intensifies fluid flow in the molten pool, thereby promoting homogeneous distribution of SiC particles. Increasing the wire feeding rate aggravates molten pool instability, and welding spatter emerges when the rate reaches 0.06 m/s. If the dual-wire gap is smaller than 2.0 mm, the two droplets merge, which leads to defective deposited morphology. The provided analyses of heat and fluid flow and the predictions of deposition morphology are helpful for the design of process parameters.