Towards implementation of alloy-specific thermo-fluid modelling for laser powder-bed fusion of Mg alloys

Multi-physics thermo-fluid modeling has been extensively used as an approach to understand melt pool dynamics and defect formation as well as optimizing the process-related parameters of laser powder-bed fusion(L-PBF).However,its capabilities for being implemented as a reliable tool for material design,where minor changes in material-related parameters must be accurately captured,is still in question.In the present research,first,a thermo-fluid computational fluid dynamics(CFD)model is developed and validated against experimental data.Considering the predicted material properties of the pure Mg and commercial ZK60 and WE43 Mg alloys,parametric studies are done attempting to elucidate how the difference in some of the material properties,i.e.,saturated vapor pressure,viscosity,and solidification range,can influence the melt pool dynamics.It is found that a higher saturated vapor pressure,associated with the ZK60 alloy,leads to a deeper unstable keyhole,increasing the keyhole-induced porosity and evaporation mass loss.Higher viscosity and wider solidification range can increase the non-uniformity of temperature and velocity distribution on the keyhole walls,resulting in increased keyhole instability and formation of defects.Finally,the WE43 alloy showed the best behavior in terms of defect formation and evaporation mass loss,providing theoretical support to the extensive use of this alloy in L-PBF.In summary,this study suggests an approach to investigate the effect of materials-related parameters on L-PBF melting and solidification,which can be extremely helpful for future design of new alloys suitable for L-PBF.

Effect of gas blowing nozzle angle on multiphase flow and mass transfer during RH refining process

A three-dimensional mathematical model was developed to investigate the effect of gas blowing nozzle angles on multiphase flow,circulation flow rate,and mixing time during Ruhrstahl-Heraeus(RH) refining process.Also,a water model with a geometric scale of 1:4 from an industrial RH furnace of 260 t was built up,and measurements were carried out to validate the mathematical model.The results show that,with a conventional gas blowing nozzle and the total gas flow rate of 40 L·min^(-1),the mixing time predicted by the mathematical model agrees well with the measured values.The deviations between the model predictions and the measured values are in the range of about 1.3%–7.3% at the selected three monitoring locations,where the mixing time was defined as the required time when the dimensionless concentration is within 3% deviation from the bath averaged value.In addition,the circulation flow rate was 9 kg·s^(-1).When the gas blowing nozzle was horizontally rotated by either 30° or 45°,the circulation flow rate was found to be increased by about 15% compared to a conventional nozzle,due to the rotational flow formed in the up-snorkel.Furthermore,the mixing time at the monitoring point 1,2,and 3 was shortened by around 21.3%,28.2%,and 12.3%,respectively.With the nozzle angle of 30° and 45°,the averaged residence time of 128 bubbles in liquid was increased by around 33.3%.

CFD study of non-premixed swirling burners: Effect of turbulence models

This research investigates a numerical simulation of swirling turbulent non-premixed combustion.The effects on the combustion characteristics are examined with three turbulence models:namely as the Reynolds stress model,spectral turbulence analysis and Re-Normalization Group.In addition,the P-1 and discrete ordinate(DO)models are used to simulate the radiative heat transfer in this model.The governing equations associated with the required boundary conditions are solved using the numerical model.The accuracy of this model is validated with the published experimental data and the comparison elucidates that there is a reasonable agreement between the obtained values from this model and the corresponding experimental quantities.Among different models proposed in this research,the Reynolds stress model with the Probability Density Function(PDF)approach is more accurate(nearly up to 50%)than other turbulent models for a swirling flow field.Regarding the effect of radiative heat transfer model,it is observed that the discrete ordinate model is more precise than the P-1 model in anticipating the experimental behavior.This model is able to simulate the subcritical nature of the isothermal flow as well as the size and shape of the internal recirculation induced by the swirl due to combustion.

Mechanically Assisted Low-Temperature Pyrolysis of Hydrocarbons

The focus of the study is experimental setups and conditions leading to pyrolysis (cracking) of such gaseous hydrocarbons as methane, mixed propane and butane, at the temperatures of the heater below 200&degC. The process was mechanically assisted by putting the substances being decomposed into a dynamic interaction with the fractal interfaces of cracks in titanium dioxide films, as well as in tin and bismuth alloy. During a trial, the alloy was periodically heated and cooled so that it changed its phase state, and fractal interfaces were created between its surface and the gases. The interaction of the gases with fractal surfaces of the alloy being produced by mechanical fracturing made it possible to obtain gas cracking even at the lower temperatures of the heater (150&degC). It should be noted that at this temperature, the heater couldn’t melt the alloy in the heated volume with the gas.

Flow field, heat transfer and inclusion behavior in a round bloom mold under effect of a swirling flow submerged entry nozzle

Flow field,heat transfer and inclusion behavior in a 700 mm round bloom mold under the effect of a swirling flow submerged entry nozzle(SEN)were investigated with the aim to enhance the casting process.The results indicate that the impinging flow phenomenon,which is commonly observed in conventional single-port SEN casting,was completely suppressed by the swirling flow SEN coming from a novel swirling flow generator design in tundish.Steel from the SEN port moved towards the mold wall in 360 direction,leading to a uniform temperature distribution in the mold.Compared to a conventional single-port SEN casting,the steel super-heat was decreased by about 5 K at the mold center,and the temperature was increased by around 3.5 K near the meniscus.In addition,the removal ratio of inclusions to the mold top surface in the swirling flow SEN casting was found to be increased.Specifically,the removal ratio of spherical inclusions with diameters of 1,10,50 and 100μm was increased by 18.2%,18.5%,22.6% and 42.7%,respectively.Furthermore,the ratio was raised by 18.2%,20.8%,21.5% and 44.1%for non-spherical inclusions,respectively.