Effect of mold and core preheating temperature on corrosion resistance of casting Al-12Si alloy U-shaped cooling channel

Temperature has an important impact on the corrosion resistance of mold with cooling channels prepared by casting method.The effect of preheating temperature of the mold and the carbon fiber core on the roughness and corrosion resistance of U-shaped cooling channels made of Al-12Si alloy was examined in depth.The experimental results suggest that as the preheating temperature increased from 273 K to 573 K,the roughness of the inner wall of the cooling channel reduced from 96.6μm to 77.0μm.When the preheating temperature continued to increase to 723 K,the roughness increased to 85.3μm.The wetting between the Al melt and the carbon fiber will reduce micro bubbles and waves on the channel wall as the preheating temperature rises,thereby reducing the roughness.However,with the further increase of preheating temperature,it will increase the solidification time of the Al melt.At this time,the carbon fiber and Al melt will take more time to react,which increases the roughness of the channel wall to a certain extent.The results of exfoliation corrosion show that the larger roughness will aggravate exfoliation corrosion.The prolongation of high temperature reaction time between the carbon fiber and the Al melt will lead to the segregation of Si,which is easy to cause intergranular corrosion.Therefore,reasonable preheating temperature has an important impact on the roughness and corrosion resistance of U-shaped cooling channels.

Effect of Different Shapes of Conformal Cooling Channel on the Parameters of Injection Molding

Cooling system improvement is important in injection molding to get betterquality and productivity. The aim of this paper was to compare the different shapes of theconformal cooling channels (CCC) with constant surface area and CCC with constantvolume in injection molding using Mold-flow Insight 2016 software. Also the CCC resultswere compared with conventional cooling channels. Four different shapes of the CCC suchas circular, elliptical, rectangular and semi-circular were proposed. The locations of thecooling channels were also kept constant. The results in terms of cooling time, cycle timereduction and improvement in quality of the product shows that no significant effect ofCCC’s shapes when surface area of CCC kept constant. On the other hand, the rectangularCCC shows better result as compared to other shapes of CCC when volume of CCC werekept constant.

Thermal Performance of Mini Cooling Channels for High-Power Servo Motor with Non-Uniform Heat Dissipation

High-power servo motor is widely employed as a necessary actuator in flight vehicles.The urgent problem to be solved restraining the working performance of servo motor is no longer the torque and power,but the heat dissipation capability under high-power working conditions,which may cause the overheat,even burn down of motor or other potential safety hazards.Therefore,a structure of mini cooling channels with appropriate channel density is designed in accordance with the non-uniform heat flux of servo motor in this paper.Combined with the regenerative cooling method,the cryogenic fuel supercritical methane is served as the coolant,which is easy to be obtained from the propulsion system,and the heat from the servo motor can be transported to the combustion for reusing.According to the actual working cases of servo motor,a numerical model is built to predict the thermal performance of cooling channels.In order to better represent the secondary flow of coolant in the cooling channels,especially the turbulent mixed flow in the manifold,the k-εRNG model with enhanced wall treatment is employed resulting from its precise capacity to simulate the secondary and wall shear flow.On this basis,the heat transfer mechanism and thermal performance of cooling channels,as well as the influence of various heat flux ratios are investigated,which can offer an in-depth understanding of restraining excessive temperature rise and non-uniformity distribution of the servo motor.By the calculation results,it can be concluded that under the adjustment of the channel density according to the corresponding heat flux,the positive role of the appropriate channel density and the manifolds on heat transfer is manifested.Moreover,the maximum temperature difference of heating wall can be kept within an acceptable range of the servo motor.The heat transfer coefficient in the manifold is nearly 2–4 times higher compared with that in the straight cooling channels.The effect of buoyancy force cannot be neglected even in the manifold with turbulent mixed flow,and the pattern of heat transfer is mixed convection one in all the flow regions.The thermal resistance R and overall Nusselt number Nu are affected remarkably by all the operation parameters studied in the paper,except the pressure,while the overall thermal performance coefficientηdemonstrates differently.The strong impact of heat flux ratio is implied on thermal performance of the cooling channels.Higher heat flux ratio results in the stronger non-uniform temperature distribution.Meanwhile,only tiny temperature differences of the fluid and inner wall in manifolds among various heat flux ratios are demonstrated,resulting from the positive effect of mixture flow on heat transfer.

A multi-objective study on the constructal design of non-uniform heat generating disc cooled by radial-and dendritic-pattern cooling channels

A three-dimensional disc model with non-uniform heat generating is built.A series of cooling channels are inserted to cool this disc which is strewn in a hierarchical pattern.To reveal thermal and flow characteristics,a composite objective function comprised of the maximum temperature difference(MTD)and pumping power is constructed.The deployment pattern of cooling channels contains two cases,i.e.,the radial-pattern and dendritic-pattern.By capitalizing on constructal design method together with finite element method,the diameter of radial-pattern cooling channels is optimized in the first place.Next,the diameter,angle coefficient and length coefficient of dendritic-pattern cooling channels are three degrees-of-freedom to be stepwise optimized at different heat generating conditions.Furthermore,NSGA-II algorithm is introduced into the multiobjective problem.Upon obtaining its Pareto optimal solution set,Topsis method is invoked to yield the optimal solutions under given weighted coefficients.The heat generation over the entire body and the volume ratio of cooling channels operate as the primary constraints.Based on these premises,constructal design will be stepwise performed by varying three degrees-offreedom.The obtained results state that more heating components or devices should be installed as close to the cooling water inlet as possible.This can further reduce MTD at the same cost of pumping power,thereby improve thermal and flow performance and prolong the lifespan of devices.As optimized with two degrees-of-freedom,the MTD is reduced by 18.6%compared with the counterpart obtained from single degree-of-freedom optimization,while the pumping power is increased by 59.8%.As optimized with three degrees-of-freedom,the MTD is decreased by 6.2%compared with the counterpart from two degrees-of-freedom optimization,while the pumping power is increased by 3.0%.It is manifest that when two sub-objectives form a composite objective,the performance improvement of one sub-objective will inevitably elicit the vitiation of the alternative.

Finite Element Analysis on the Injection Molding and Productivity of Conformal Cooling Channel

The study proves that the conformal cooling channel can overcome the disadvantages of the conventional cooling channel resulting from the limitation in complicated shape.The simulation analyses of the fragrance lamp with different cooling layouts show that the conformal cooling channel can offer a more uniform heat dissipation,lower volume shrinkage and shorter time to freeze than the conventional channel,which indicates significantly improvements in productivity and quality.

Failure mode analysis on compression of lattice structures with internal cooling channels produced by laser powder bed fusion

Conformal cooling coils have been developed during the last decades through the use of additive manufacturing(AM)technologies.The main goal of this study was to analyze how the presence of an internal channel that could act as a conformal cooling coil could affect compressive strength and quasi-elastic gradient of AlSi10Mg lattice structures produced by laser powder bed fusion(LPBF).Three different configurations of samples were tested in compression at 25℃ and 200℃.The reference structures were body centered cubic(BBC)in the core of the samples with vertical struts along Z(BCCZ)lattices in the outer perimeter,labelled as NC samples.The main novelty consisted in inserting a straight elliptical channel and a 45°elliptical channel inside the BCCZ lattice structures,labelled as SC and 45C samples respectively.All the samples were then tested in as-built(AB)condition,and after two post process heat treatments,commonly used for AlSi10Mg LPBF industrial components,a stress relieving(SR)and a T6 treatment.NC lattice structures AB exhibited an overall fragile fracture and therefore the SC and 45C configuration samples were tested only after thermal treatments.The test at 25℃ showed that all types of samples were characterized by negligible variations in their quasi-elastic gradients and yield strength.On the contrary,the general trend of stress-strain curves was influenced by the presence of the channel and its position.The test at 200℃ showed that NC,SC and 45C samples after SR and T6 treatments exhibited a metal-foam like deformation.

Cycle Time Reduction in Injection Molding by Using Milled Groove Conformal Cooling

This paper presents simulation study on Milled Grooved conformal cooling channels(MGCCC)in injection molding.MGCCC has a more effective cooling surface area which helps to provide efficient cooling as compared to conventional cooling.A case study of Encloser part is investigated for cycle time reduction and quality improvement.The performance designs of straight drilled are compared with MGCCC by using Autodesk Moldflow Insight(AMI)2016.The results show total 32.1% reduction of cooling time and 9.86% reduction of warpage in case of MGCCC as compared to conventional cooling.

Numerical Study of High Heat Flux Performances of Flat-Tile Divertor Mock-ups with Hypervapotron Cooling Concept

The hypervapotron（HV）,as an enhanced heat transfer technique,will be used for ITER divertor components in the dome region as well as the enhanced heat flux first wall panels.W-Cu brazing technology has been developed at SWIP（Southwestern Institute of Physics）,and one W/CuCrZr/316 LN component of 450 mm×52 mm×166 mm with HV cooling channels will be fabricated for high heat flux（HHF） tests.Before that a relevant analysis was carried out to optimize the structure of divertor component elements.ANSYS-CFX was used in CFD analysis and ABAQUS was adopted for thermal-mechanical calculations.Commercial code FE-SAFE was adopted to compute the fatigue life of the component.The tile size,thickness of tungsten tiles and the slit width among tungsten tiles were optimized and its HHF performances under International Thermonuclear Experimental Reactor（ITER） loading conditions were simulated.One brand new tokamak HL-2M with advanced divertor configuration is under construction in SWIP,where ITER-like flat-tile divertor components are adopted.This optimized design is expected to supply valuable data for HL-2M tokamak.

Corrosion Behavior of the S136 Mold Steel Fabricated by Selective Laser Melting

The selective laser melting(SLM) method has a great potential for fabricating injection mold with complex structure. However, the microstructure and performance of the SLM molds show significantly di erent from those manufac?tured by traditional technologies. In this study, the microstructure, hardness and especially corrosion behavior of the samples fabricated by SLM and casting were investigated. The XRD results exhibit that the γ?Fe phase is only obtained in the SLM parts, and the α?Fe peak slightly moves to low di raction angle compared with casting counterparts. Due to the rapid cooling rate, the SLM samples have fine cellular microstructures while the casting ones have coarse grains with obvious elements segregation. Besides, the SLM samples show anisotropy, hardness of side view and top view are 48.73 and 50.31 HRC respectively, which are 20% higher than that of casting ones. Corrosion results show that the SLM samples have the better anti?corrosion resistance(in a 6% FeCl3 solution for 48 h) but the deeper corrosion pits than casting ones. Finally, the performance of the SLM molds could meet the requirement of injecting production. Moreover, the molds especially present a significant decrease(20%) of cooling time and increases of cooling uniform?ity due to the customized conformal cooling channels.