Numerical Simulation of Temperature Field during Electron Beam Cladding for NiCrBSi on the Surface of Inconel 718

This study investigates the Inconel 718 alloy coated with NiCrBSi powder using the ABAQUS software. An accurate conical heat source model is constructed based on the three-dimensional Fourier heat conduction law. The heat source subroutine Dflux.for is successfully integrated to achieve a highly realistic simulation of the welding heat source. Using this model, the analysis focuses on the temperature distribution in electron beam melting. Furthermore, the accuracy and reliability of the simulation are validated through actual coating experiments. By examining the impact of various procedural factors on the temperature distribution, it is found that optimal coating results and a tightly formed elliptical molten zone are attained at an electron beam current of 18 mA, and the scanning speed is 300 mm/min. The peak temperature in the melt pool in the coating area is 5087 K, while the lowest temperature on the isothermal in the heat-affected zone is 1409 K. Over time, there is a swift rise in temperature for the data points taken along both the X and Z trajectories, followed by rapid cooling after rapid heating. Coating experiments conducted under the optimal parameters demonstrate a dense coating layer and good bonding with the substrate, thereby validating the accuracy of the simulation.