Article
Engineering, Multidisciplinary
Tao Yu, Jidong Zhao
Summary: Laser powder bed fusion is the future of metal additive manufacturing. However, the lack of high-fidelity prediction tools hinders its development. We have developed a computational tool that can accurately simulate the multiphase and multiphysics processes in selective laser melting. This tool has innovative features and can reproduce key observations from experiments, making it a valuable tool for design and optimization of laser powder bed fusion.
COMPUTER METHODS IN APPLIED MECHANICS AND ENGINEERING
(2022)
Article
Engineering, Industrial
Wessel W. Wits, Emiel Amsterdam
Summary: In laser powder bed fusion, multi-material mixing and elemental diffusion were studied for the fabrication of functionally graded structures. An adapted recoater was used to deposit powder from multiple sources, creating a more gradual material transition. Homogenization heat treatment enhanced elemental diffusion, resulting in a gradual material transition without a distinct interface.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Industrial
Rocco Lupoi, William M. Abbott, Ramsankar Senthamaraikannan, Sean McConnell, John Connolly, Shuo Yin, Ramesh Babu Padamati
Summary: This article introduces a novel method for additive manufacturing of metal parts called MAPS, which uses rollers of a new composite material as feedstock. It addresses some drawbacks of traditional PBF methods and is capable of producing materials on par with traditional methods without the need for loose powders, thereby reducing safety risks.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Multidisciplinary
Tao Yu, Jidong Zhao
Summary: A semi-coupled resolved Computational Fluid Dynamics (CFD) and Discrete Element Method (DEM) is proposed to simulate granular media problems involving thermal-induced phase changes and particle-fluid interactions. Validated through simulations of a powder-based selective laser melting (PB-SLM) process, the method examines the effects of key SLM input parameters on melting and provides a physically based, high-fidelity computational approach for future PB-SLM additive manufacturing.
COMPUTER METHODS IN APPLIED MECHANICS AND ENGINEERING
(2021)
Article
Engineering, Manufacturing
Dengzhi Yao, Xizhong An, Haitao Fu, Hao Zhang, Xiaohong Yang, Qingchuan Zou, Kejun Dong
Summary: This article studied the spreading of 316L stainless steel powder during printing through 3D particulate scale dynamic simulations, identifying factors affecting powder bed quality and optimized conditions such as blade moving speed and particle size. The simulation results showed that optimal conditions lead to a more uniform and denser powder bed.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Manufacturing
Sven Mueller, Peer Woizeschke
Summary: This study investigates the thermal joining of aluminum and titanium sheets using a laser powder bed fusion machine. Despite the melting of materials, there is great potential for high interfacial tensile strength in laser fusion of titanium powder on aluminum substrates.
ADDITIVE MANUFACTURING
(2021)
Article
Chemistry, Physical
Filip Vele, Michal Ackermann, Vaclav Bittner, Jiri Safka
Summary: The study investigates the impact of SLM technology on the porosity and hardness of AISI H13 tool steel, identifying the minimum energy density required for a satisfactory density and hardness level, and proposing phenomenological models based on experimental data analysis.
Article
Materials Science, Multidisciplinary
P. Ashwath, M. Anthony Xavior, Andre Batako, P. Jeyapandiarajan, J. Joel
Summary: Additive Manufacturing (AM) and Selective Laser Melting (SLM) are advanced manufacturing methods widely used in the aerospace industry. Current research focuses on using SLM to fabricate Al-Si-10Mg aluminum alloy and study the effects of scanning speed and build orientation on the mechanical strength and surface finish of the components. This research is of importance for dynamic applications.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Multidisciplinary Sciences
Arif Balci, Furkan Kucukaltun, M. Fatih Aycan, Yusuf Usta, Teyfik Demir
Summary: The study produced trabecular bone models with a designable microstructure using selective laser melting, scanned them with Micro-CT, and aligned 3D models to determine deviations. It was observed that deviations decreased with angles above 60 degrees, while increasing significantly with sizes below 150 microns.
ARABIAN JOURNAL FOR SCIENCE AND ENGINEERING
(2021)
Article
Nanoscience & Nanotechnology
D. Palmeri, G. Buffa, G. Pollara, L. Fratini
Summary: Recent research has focused on new production technologies to optimize production and reduce costs, including additive manufacturing processes like Selective Laser Melting (SLM). However, literature analysis shows conflicting results in determining the optimal building orientation for maximizing mechanical properties and minimizing porosity. A study evaluated the building orientation effect and identified three geometrical parameters to understand the causes of decreased mechanical properties due to incorrect orientation angle choices.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Review
Engineering, Manufacturing
Abdelkrim Bouabbou, Sebastien Vaudreuil
Summary: Selective laser melting (SLM) is a widely used and versatile technique for additive manufacturing of metallic parts. This review focuses on the interaction between laser and metal powders, highlighting the advancements in powder-scale modeling and simulation, as well as the generation of virtual powder beds and multi-physics computations. The use of meta-modeling and machine learning for process optimization is critically discussed.
VIRTUAL AND PHYSICAL PROTOTYPING
(2022)
Article
Engineering, Manufacturing
Yuhang Wu, Meng Li, Ju Wang, Yang Wang, Xizhong An, Haitao Fu, Hao Zhang, Xiaohong Yang, Qingchuan Zou
Summary: This paper numerically reproduces the whole process of laser powder-bed-fusion (LPBF) additive manufacturing (AM) for molybdenum (Mo) material. It calibrates the parameters of Mo powder and studies the powder spreading using a discrete element model (DEM). The laser melting of the spread powder bed is simulated by computational fluid dynamics (CFD). Then, a back propagation neural network (BPNN) model is built for powder bed quality and molten track property prediction and evaluation. The results show the importance of adjusting spreading velocity and gap height in achieving optimal powder bed structure, and reveal the main factors affecting powder bed quality and molten track performance.
ADDITIVE MANUFACTURING
(2022)
Article
Engineering, Mechanical
Liping Ding, Shujie Tan, Wenliang Chen, Yaming Jin, Yicha Zhang
Summary: This study investigates the manufacturability of extremely fine porous structures in the SLM process, revealing the importance of process parameters and printing planning on the results. It proposes a method for manufacturability analysis and printing parameter control of fine porous structures.
RAPID PROTOTYPING JOURNAL
(2021)
Article
Engineering, Mechanical
Qimin Shi, Yi Sun, Shoufeng Yang, Jeroen Van Dessel, Heinz-Theo Luebbers, Shengping Zhong, Yifei Gu, Michel Bila, Titiaan Dormaar, Joseph Schoenaers, Constantinus Politis
Summary: A multidimensional and comprehensive analysis of the in-vivo fatigue failure mechanism of an SLM-fabricated Ti6Al4V mandible reconstruction plate reveals that surface defects and maximal stress caused by implant design are the main factors for crack initiation and propagation, showing a combined brittle/ductile fracture mode. The process is influenced by Ca/P/O deposits and hydrogen embrittlement under the biological environment.
ENGINEERING FAILURE ANALYSIS
(2021)
Article
Engineering, Manufacturing
P. Didier, G. Le Coz, G. Robin, P. Lohmuller, B. Piotrowski, A. Moufki, P. Laheurte
Summary: The study emphasizes the importance of using additively manufactured support structures as machining fixtures to improve the stability of Ti-6Al-4 V parts milling. The stiffness of the support structures is crucial for the machining operation, as milling can induce chatters and the mechanical properties and topology of supports need to be considered in the design process.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Nanoscience & Nanotechnology
Yihe Huang, Margherita Sepioni, David Whitehead, Zhu Liu, Wei Guo, Xiangli Zhong, Heng Gu, Lin Li
Article
Chemistry, Physical
Jiayang Gu, Ruifeng Li, Shungao Chen, Yuhao Zhang, Shujin Chen, Heng Gu
Article
Engineering, Industrial
Harley Oliff, Ying Liu, Maneesh Kumar, Michael Williams, Michael Ryan
JOURNAL OF MANUFACTURING SYSTEMS
(2020)
Article
Automation & Control Systems
Mulla Ahmet Pekok, Rossitza Setchi, Michael Ryan, Quanquan Han, Dongdong Gu
Summary: Selective laser melting (SLM) offers significant benefits compared to traditional manufacturing techniques, but the limited materials available for SLM production restrict the industrial adoption of the technology. This study investigates the effect of laser parameters on the mechanical and microstructural properties of aluminium 2024 alloy manufactured using SLM, revealing insights into crack formation and microhardness variations.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Chemical
Heng Gu, Chao Wei, Lin Li, Michael Ryan, Rossitza Setchi, Quanquan Han, Lili Qian
Summary: A DEM-CFD model was established to understand the forming mechanisms of defects in LPBF of multi-material and FGM, leading to the discovery of causes for various defects and optimization of process parameters for defect-free FGM structures.
ADVANCED POWDER TECHNOLOGY
(2021)
Article
Energy & Fuels
Lili Qian, Jun Ni, Zhiyang Xu, Bin Yu, Shuang Wang, Heng Gu, Dong Xiang
Summary: The study found that the optimal operating parameters for hydrothermal liquefaction are a moisture content of 70-90%, a reaction pressure of 20 MPa, and a reaction temperature of 250-350 degrees Celsius, resulting in high biocrude yield and energy recovery. Additionally, adjusting the reactor's critical diameter based on different flow rates can prevent reactor blockages.
Article
Engineering, Manufacturing
Mulla Ahmet Pekok, Rossitza Setchi, Michael Ryan, Heng Gu, Quanquan Han, Dongdong Gu
Summary: This paper investigates the effect of milling time on the morphology and flowability of graphene-reinforced aluminum alloy powders. The study shows that 4 hours of milling effectively disperses graphene nanoplatelets and improves the flowability of the powder. Additionally, milling reduces the crystallite size and increases the microhardness of the powder.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2022)
Article
Thermodynamics
Lili Qian, Jun Ni, Ming Luo, Yi Lu, Shuang Wang, Chuan Yuan, Kai Zhu, Bo Zhang, Heng Gu
Summary: This study investigates the hydrothermal liquefaction of phycocyanin under a wide range of conditions and develops machine learning models to predict biocrude yield. The results show that fast HTL at 500°C and 40 s produces the highest biocrude yield and energy recovery. Biocrude predominantly consists of nitrogenous heterocyclic compounds. Water quality analysis reveals the need for further treatment of by-products.
ENERGY CONVERSION AND MANAGEMENT
(2023)
Article
Thermodynamics
Heng Gu, Tapio Vaisto, Chao Wei, Lin Li, Xudong Ren, Lili Qian
Summary: Laser beam reflection has a significant impact on temperature development and microstructure evolution in multi-pass narrow gap laser welding (NGLW). A ray-tracing based CFD and cellular automaton modelling framework was established to investigate the impact of laser beam reflection on molten pool formation and microstructure evolution. The simulation results showed that laser beam absorption in NGLW is greater than laser metal deposition (LMD) and smaller than laser powder bed fusion (LPBF) process. The analysis also revealed that laser beam reflection affects the formation of defects and grain structure development.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2023)
Proceedings Paper
Green & Sustainable Science & Technology
Ben Mason, Michael Ryan, Rossi Setchi, Abhishek Kundu, Wayne Nishio Ayre, Debajyoti Bhaduri
Summary: A novel multi-step laser polishing strategy is developed for reducing the surface roughness of additively manufactured aluminium alloy parts. The strategy combines laser ablation and smoothing steps and achieves significant reductions in roughness.
SUSTAINABLE DESIGN AND MANUFACTURING, SDM 2022
(2023)
Proceedings Paper
Automation & Control Systems
Yixin Li, Fu Hu, Michael Ryan, Ray Wang, Ying Liu
Summary: This paper introduces a method using knowledge distillation technique to predict AM energy consumption, training models through a teacher-student architecture to reduce computational burdens while maintaining model performance. A case study demonstrates the feasibility and effectiveness of this approach.
Article
Thermodynamics
Mahsa Taghavi, Swapnil Sharma, Vemuri Balakotaiah
Summary: This study investigates the natural convection effects in the insulation layers of spherical storage tanks and their impact on the tanks' performance. The permeability and Rayleigh number of the insulation material are considered as key factors. The results show that as the Rayleigh number increases, new convective cells emerge and cause the cold boundary to approach the external hot boundary. In the case of large temperature differences, multiple solutions may coexist.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Jinyang Xu, Fangjun Hong, Chaoyang Zhang
Summary: This study introduces a self-induced jet impingement device for enhancing pool boiling performance in high power electronic cooling. Through visualization and parametric investigations, the effects of this device on pool boiling performance are studied, revealing the promotion of additional liquid supply and vapor exhausting. The flow rate of the liquid jet is found to positively impact boiling performance.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Wenchao Ke, Yuan Liu, Fissha Biruke Teshome, Zhi Zeng
Summary: Underwater wet laser welding (UWLW) is a promising and labor-saving repair technique. A thermal multi-phase flow model was developed to study the heat transfer, fluid dynamics, and phase transitions during UWLW. The results show that UWLW creates a water keyhole, making the welding environment similar to in air laser welding.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Xingrong Lian, Lin Tian, Zengyao Li, Xinpeng Zhao
Summary: This study investigates the heat transfer mechanisms in natural fiber-derived porous structures and finds that thermal radiation has a significant impact on the thermal conductivity in low-density regions, while natural convection rarely occurs. Insulation materials derived from micron-sized natural fibers can achieve minimum thermal conductivity at specific densities. Strategies to lower the thermal conductivity include increasing porosity and incorporating nanoscale pores using nanosize fibers.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Yasir A. Malik, Kilian Koebschall, Stephan Bansmer, Cameron Tropea, Jeanette Hussong, Philippe Villedieu
Summary: Ice crystal icing is a significant hazard in aviation, and accurate modeling of sticking efficiency is essential. In this study, icing wind tunnel experiments were conducted to quantify the volumetric liquid water fraction, sticking efficiency, and maximum thickness of ice layers. Two measurement techniques, calorimetry and capacitive measurements, were used to measure the liquid water content and distribution in the ice layers. The experiments showed that increasing wet bulb temperatures and substrate heat flux significantly increased sticking efficiency and maximum ice layer thickness.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Jinqi Hu, Tongtong Geng, Kun Wang, Yuanhong Fan, Chunhua Min, Hsien Chin Su
Summary: This study experimentally examined the heat dissipation of vibrating fans and demonstrated its inherent mechanism through numerical simulation. The results showed that the flow fields induced by the vibrating blades exhibited pulsating features and formed large-scale and small-scale vortical structures, significantly improving heat dissipation. The study also identified the impacts of different blade structures and developed a trapezoidal-folding blade, which effectively reduced the maximum temperature of the heat source and alleviated high-temperature failure crisis.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Dan-Dan Su, Xiao-Bin Li, Hong-Na Zhang, Feng-Chen Li
Summary: The boiling heat transfer of low-boiling-point working fluid is a common heat dissipation technology in electronic equipment cooling. This study analyzed the interfacial boiling behavior of R134a under different conditions and found that factors such as the initial thickness of the liquid film, solid-liquid interaction force, and initial temperature significantly affect the boiling mode and thermal resistance.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Jinyi Wu, Dongke Sun, Wei Chen, Zhenhua Chai
Summary: A unified lattice Boltzmann-phase field scheme is proposed to simulate dendrite growth of binary alloys in the presence of melt convection. The effects of various factors on the growth are investigated numerically, and the model is validated through comparisons and examinations.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Shaokun Ge, Ya Ni, Fubao Zhou, Wangzhaonan Shen, Jia Li, Fengqi Guo, Bobo Shi
Summary: This study investigated the temperature distribution of main cables in a suspension bridge during fire scenarios and proposed a prediction model for the maximum temperature of cables in different lane fires. The results showed that vehicle fires in the emergency lane posed a greater thermal threat to the cables.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Shuang-Ying Wu, Shi-Yao Zhou, Lan Xiao, Jia Luo
Summary: This paper investigates the two-phase flow and heat transfer characteristics of low-velocity jet impacting on a cylindrical surface. The study reveals that the heat transfer regimes are non-phase transition and nucleate boiling with the increase of heat transfer rate. The effects of jet impact height and outlet velocity on local surface temperatures are pronounced at the non-phase transition stage. The growth rates of heat transfer rate and liquid loss rate increase significantly from the non-phase transition to nucleate boiling stage.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Emad Hasani Malekshah, Wlodzimierz Wlodzimierz, Miros law Majkut
Summary: Cavitation has significant practical importance and can be controlled by air injection. This study investigates the natural to ventilated cavitation process around a hydrofoil through numerical and experimental methods. The results show that the location and rate of air injection have a meaningful impact on the characteristics of cavitation.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Feriel Yahiat, Pascale Bouvier, Antoine Beauvillier, Serge Russeil, Christophe Andre, Daniel Bougeard
Summary: This study explores the enhancement of mixing performance in laminar flow equipment by investigating the generation of chaotic advection using wall deformations in annular geometries. The findings demonstrate that the combined geometry can achieve perfect mixing at various Reynolds numbers.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Hui He, Ning Lyu, Caihua Liang, Feng Wang, Xiaosong Zhang
Summary: This study investigates the condensation, frosting, and defrosting processes on superhydrophobic surfaces with millimeter-scale structures. The results reveal that the structures can influence the growth and removal of frost crystals, with the bottom grooves creating a frost-free zone and conical edges promoting higher frost crystal heights. Two effective methods for defrosting are observed: hand-lifting the groove and airfoil retraction contraction on protruding structures. This research provides valuable insights into frost formation and defrosting on millimeter-structured superhydrophobic surfaces, with potential applications in anti-frost engineering.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Thiwanka Arepolage, Christophe Verdy, Thibaut Sylvestre, Aymeric Leray, Sebastien Euphrasie
Summary: This study developed two thermal concentrators, one with a 2D design of uniform thickness and another with a 3D design, using the coordinate transformation technique and metamaterials. By structuring the thermal conductor, the desired local density-heat capacity product and anisotropic thermal conductivities were achieved. The homogenized thermal conductivities were obtained from finite element simulations and cylindrical symmetry consideration. A 3D concentrator was fabricated using 3D metal printing and characterized using a thermal camera. Compared to devices that solely consider anisotropic conductivities, the time evolution characteristics of the metadevice designed with coordinate transformation were closer to those of an ideal concentrator.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)
Article
Thermodynamics
Liangyuan Cheng, Qingyang Wang, Jinliang Xu
Summary: In this study, we investigated the supercritical heat transfer of CO2 in a horizontal tube with a diameter of 10.0 mm, covering a wide range of pressures, mass fluxes, and heat fluxes. The study revealed a non-monotonic increase in wall temperatures along the flow direction and observed both positive and negative wall temperature differences between the bottom and top tube. The findings were explained by the thermal conduction in the solid wall interacting with the stratified-wavy flow in the tube.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2024)