Numerical simulation of ultrasound assisted powder feed flow in coaxial nozzle used in direct metal deposition process

Numerical simulation of ultrasound assisted powder feed flow in coaxial nozzle used in direct metal deposition process | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Numerical simulation of ultrasound assisted powder feed flow in coaxial nozzle used in direct metal deposition process Sergey Nikiforov, Ivan Shvarts, Vladislav Morozov, Dmitry Kaydarov, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7482633/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 30 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract This study investigates a hybrid gas-ultrasonic powder feed system for coaxial nozzles in Direct Metal Deposition (DMD) process. We present a coupled experimental and numerical approach to analyze the effects of ultrasonic vibration (40 kHz) on powder stream characteristics such as mass flow rate, focal plane position, and particle distribution uniformity. A numerical model was developed using the Discrete Phase Method (DPM) with empirically calibrated restitution coefficients to account for ultrasound-induced particle-wall interactions, avoiding costly structural dynamics simulations. Experimental validation was performed using a modified coaxial nozzle with integrated piezoelectric actuators to induce ultrasonic vibrations on powder feed channel. Results demonstrate that ultrasound vibrations reduces particle-wall adhesion by 10–15%, increasing mean particle velocity by 17–22%. The hybrid mode achieved an 8% higher peak powder concentration in the focal zone. The predicted focal height and diameter of the powder stream in the numerical model lies within gathered experimental data. This work provides a validated framework for optimizing ultrasonic powder delivery systems in additive manufacturing, offering significant improvements in process stability and deposition quality. metal powder direct energy deposition process coaxial nozzle ultrasound vibration numerical simulation Full Text Cite Share Download PDF Status: Published Journal Publication published 30 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 16 Nov, 2025 Reviewers agreed at journal 04 Oct, 2025 Reviewers invited by journal 10 Sep, 2025 Editor assigned by journal 08 Sep, 2025 First submitted to journal 03 Sep, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7482633","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":513191686,"identity":"268812a3-567a-46cc-bd52-416e4fb4575d","order_by":0,"name":"Sergey 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