A novel method of utilizing static mixer to obtain mixing homogeneity of multi-species powders in laser metal deposition

Real-time mixing of multi-species powder challenges Laser Metal Deposition (LMD) of Functionally Graded Materials (FGMs). The current work proposes a novel method of using a static mixer to realize rapid, uniform multi-species powder mixing. Firstly, copper powder and 316L stainless steel powder are selected to complete the powder mixing observation experiment with Scanning Electron Microscope (SEM) and Energy Dispersive Spectrometer (EDS). Secondly, computational fluid dynamics and particle mixing simulation models are used to analyze the flow field and particle motion characteristics in the static mixer. Finally, LMD experiment and metallographic observation are carried out with 316L stainless steel powder and WC powder to verify the feasibility of the static mixer. This study provides a theoretical and practical basis for powder mixing in laser processing with a static mixer. The conclusions can also be applied to other processing fields requiring real-time and uniform mixing of multi-species powders.