The numerical simulation of the movements and thermal states of atomized metal droplets in the spray forming process

Numerical simulation was performed in an atomizing chamber to investigate the movements and thermal states of the atomized metal droplets in the spray forming process. The velocity, temperature and solid fractions of metal droplets with different diameters and under different atomizing pressures were investigated. The results indicate that a higher atomizing pressure results in the increased flying velocity of the metal droplets and a decrease in the cone-shaped angle formed by their flight paths. Synchronously, the cooling of the metal droplets is accelerated and the time of the complete solidification process is shortened. Under the same atomization pressure, large metal droplets have a lower flying speed and a lower rate of temperature decrease in the atomizing chamber than small metal droplets. In addition, metal droplets flying along the edge of the atomizing region cool faster than those flying in the core region.

Numerical Simulation of Molten Metal Droplet Behavior in Gas Metal Arc Welding by Three-Dimensional Incompressible Smoothed Particle Hydrodynamics Method

The numerical model was developed using a SPH (Smoothed Particle Hydrodynamics) method and the projected transfer phenomena during a GMA (Gas Metal Arc) welding were simulated by the model to clarify mechanisms of the phenomena. As a result, the droplet transfer mode obtained from this calculation was regarded as a projected transfer mode in which the liquid column grew about 1 mm and a droplet grew up until its diameter became large the same as a wire diameter,?after that it was detached from the tip of the column. In addition, 10 droplets were formed for 0.1 s through these growth and detachment processes at the tip of a wire. To compare with the numerical results, actual GMA welding was carried out and molten metal droplet transfers were taken by high speed camera. The diameter of a wire, the length of a liquid column, the velocity of a droplet right before it reached a weld pool obtained by simulation showed good agreement with experiment.

Hard-magnetic liquid metal droplets with excellent magnetic field dependent mobility and elasticity

Magnetic liquid metal droplets(MLMDs)have been proven to be very important in many fields such as flexible electronics and soft robotics.Usually,soft magnetic particles such as nickel(Ni)and iron(Fe)are mixed or suspended into the liquid metal to obtain soft MLMDs(S-LMDs),which can be easily manipulated under the magnetic field due to the favorable deformability and flexibility.In addition,hard magnetic particles such as neodymium iron boron(Nd Fe B)with a high residual magnetization can also be dispersed into the liquid metal and the hard MLMDs(H-LMDs)become more compact due to the interaction between internal particles induced by remanence.This work reports a kind of H-LMDs with high surface tension,high flexibility and mechanical robustness,whose electrical conductivity and strength are better than the S-LMDs.Under the magnetic field,the H-LMDs have a faster response time(0.58 s)and a larger actuating velocity(4.45 cm/s)than the S-LMDs.Moreover,the H-LMDs show excellent magnetic controllability,good elasticity and favorable mobility,as demonstrated by magnetically actuated locomotion,bounce tests and rolling angle measurements.Finally,the droplets can be further applied in wheeldriven motors and micro-valve switches,which demonstrates their high application potential in robotic manipulation and microfluidic devices.

A Simple Method to Measure the Contact Angle of Metal Droplets on Graphite

The determination of solid–liquid interfacial tension plays an important role in science and technology.Here,we propose a simple method to directly measure the contact angle between metal droplets and a graphite substrate for the determination of metal–graphite interfacial tension.The proposed method involves the synthesis of micro-and nanosized metal droplets on graphite by arc melting.Owing to its small volume,the rapid cooling of the prepared metal droplets on the graphite substrate leads to the freezing of equilibrium contact confguration after solidifcation.We observe that the measured contact angle between micro-and nanosized Au(or Ag)particles and the graphite substrate is almost size independent,even though the size of the particles synthesized herein is 1–3 orders of magnitude smaller than that studied in previous works.In addition,the interfacial tensions of Au and Ag on the step edges(edge plane)of graphite are found to be larger than that on the(0001)plane(basal plane).The proposed method provides a simple approach to determine the solid–liquid interfacial tension and may be efective in the study of interface related science and technology.

Controllable dispersion and reunion of liquid metal droplets

Liquid metal(LM) micro-droplets have been widely used in microfluidics, drug-loaded nano-system and micro-nano machine due to its excellent properties. However,there still exist difficulties in succinctly dispersing a bulk of LM into micro-droplets due to the large interfacial tension.Besides, the controllable switching between droplet dispersion and reunion is yet to be realized. Herein, a practical and efficient method for dispersing LM was proposed and the controllable switching between dispersion and reunion of LM droplets was achieved. LM micro-droplets were produced by vibrating the LM immersed in a mixture of N,N-dimethylformamide(DMF) and polyvinyl chloride(PVC). The experimental results show that the size distribution of LM micro-droplets could be tuned by controlling the vibration frequency. More intriguingly, the dispersion and reunion of LM droplets can be switched intelligently through tuning the vibration frequency and amplitude. Furthermore, optical properties of the LM micro-droplet coating were evaluated to display potential applications. A self-driven motion of PVCcoated LM could be achieved by utilizing the produced LM micro-droplets based on the Marangoni effect, which holds promising value for developing future transport tool of LM droplets. The present work suggests an entirely feasible method for dispersing and utilizing LM droplets, which is of great significance for promoting the development of LM micro-droplet science and technology.

Study of porosity tendency in the Cr-Ni austenitic weld based on inclusion’s characteristic in the droplet

The effect of nonmetallic inclusions in the droplet of the stainless steel covered electrode on the porosity was researched.The result shows that the nonmetallic inclusions in the droplet are spherical,their composition is different from the one of slag and the inclusions have the character of “inner formation”.When the ratio of rutile to ilmenite in the coated material is increased, the droplet becomes coarse, the content of nonmetallic inclusion in the droplet decreases,and the porosity sensitivity in the weld metal also decreases.When the ratio of fledspar to ilmenite in the coated material is increased, the droplet becomes fine,the content of nonmetallic inclusion in the droplet increases, and the porosity sensitivity in the weld metal increases. When the ratio of Fe_2O_3 to ilmenite in the coated material is increased, the droplet becomes fine, the content of nonmetallic inclusion decreases, while the porosity sensitivity does not reduce.

Mesoscopic numerical computation model of air-diffusion electrode of metal/air batteries

This work creates a droplet battery model based on the electrolyte performance in the porous electrode, studies the current density on the mesoscopic scale, and explains how the mesoscopic structure of the porous electrode influences the current density on the air-diffusion electrode. Near the three-phase line, there is a strong band containing nearly 80% current. For porous electrodes, the total current is proportional to the length of the strong band. Thus, it can be inferred that on the macroscopic scale, the longer the total length of the strong band on unit area is, the larger the current density is.

STUDY ON METAL TRANSFER MODES OF SELF-SHIELDED FLUX-CORED WELDING WIRE

Metal transfer behavior of six kinds of self shielded flux cored wire(SSFCW) is studied using the apparatus of SSFCW high speed photography self made. Six kinds of metal transfer modes of SSFCW were obtained through observation for high speed photograph film and analysis. It is believed that the research is of magnificent for improving operative performance and mechanical properties of SSFCW and dynamics characteristic of welding power.

基于工程应用的CW-GMAW熔滴过渡形态表征

综述了涉及工程应用的冷丝熔化极气体保护焊(Cold wire gas metal arc welding,CW-GMAW)熔滴过渡形态特征。结果表明,在大电流、强规范、富氩混合气体保护下,CW-GMAW工艺的熔滴过渡形态呈喷射过渡;当电流较小、电弧电压较低时,可能为滴状过渡,甚至在弧压很低时,呈现短路过渡形态。该工艺电弧发生偏向冷丝的位移,弧长变短甚至发生短路,与冷丝送进速率比增高及冷丝在电弧中产生大量金属蒸气时弧柱电阻下降有关。在具有富氩混合保护气体的相同工艺参数下,CWGMAW转变电流比GMAW降低了4%~7%。焊接工艺参数对CW-GMAW和GMAW工艺熔滴过渡形态的影响规律大致相近,但前者因涉及冷丝送进速率比和电极焊丝送进速度,以及它们的匹配等,使焊接电流的影响更为复杂。

喷印金属双液滴撞击固体形成气泡的模拟研究

喷墨打印镓金属液滴撞击固体表面时会产生空气夹带,造成气泡沉积出现喷墨打印导线不互联现象,深入理解气泡形成的影响因素是解决此问题的关键。为消除气泡,提高打印导线互联性,本研究使用Ansys Fluent软件,采用VOF耦合水平集方法,建立了二维镓金属双液滴撞击固体铜基板过程的仿真模型,研究了水平壁面温度、双液滴间距、倾斜壁面角度、倾斜壁面温度等参数对金属双液滴撞击固体壁面形成气泡过程的影响规律。研究结果表明,对于水平基板,在不同基板温度下气泡的大小呈现双向变化,金属双液滴间距的增加更有利于液滴铺展。当金属双液滴间距S=D_(0)-2.38D_(0)时,有气泡形成;当S=2.38D_(0)-2.5 D_(0)时,液滴铺展出现断裂,且气泡随温度的增加没有明显变化;当金属双液滴间距S=2.6 D_(0)时,随着温度的增加不再产生气泡,此时喷墨打印液滴表现出最佳精度,提高了打印导线的互联性。对于倾斜基板,使用参数韦伯数(We⊥)和参数(K⊥)表征金属双液滴形成的气泡,当撞击倾斜壁面韦伯数We⊥>15、K⊥>0.035时,液滴会在固体表面上形成气泡;当We⊥>16、K⊥>0.04时,形成的气泡直径随壁面温度的增加而减小;当15<We⊥<16、0.035<K⊥<0.04时,液滴出现铺展断裂,并且气泡直径随着壁面温度的增加而减小;当5<We⊥<15、0.015<K⊥<0.035时,液滴铺展断裂且气泡直径变大;当We⊥<5、K⊥<0.01时,液滴在基板形成的气泡消失,此时为喷墨打印液滴的最佳精度,可提高打印导线的互联性。该研究为优化喷墨打印金属液滴的工艺提供了重要理论依据,有望在实际应用中消除气泡,进一步提高喷墨打印导线的互联性。

镓基液态金属基柔性传感材料的制备研究进展

随着人工智能可穿戴技术的快速发展,带动了具备可拉伸、可压缩和可扭曲特性的柔性传感材料的蓬勃兴起。镓基液态金属(LM),由于其卓越的导电性、导热性、流动性、高表面张力和可塑性等特点,已被广泛应用于制备柔性传感材料。然而,有关镓基液态金属用于制备柔性传感材料的方法,特别是与柔性基体材料复合,迄今缺乏全面的综述。着重介绍了镓基液态金属用于柔性传感材料的制备方法,包括直接结合法、液滴法和液态金属作为引发剂法。其次,对镓基液态金属柔性传感材料应用的最新进展进行探讨。讨论了镓基液态金属柔性传感材料在可回收利用方面取得的进展。最后,就目前研究中仍存在的问题提出建议,并对未来进行展望。

金属有机框架多面体微颗粒自组装超结构的设计策略

周期性超结构通常具有优异的光学性能,在光子晶体学、催化、传感等领域具有重要意义。在此,采用了声悬浮法和点滴法来探索多维有序金属有机框架(MOF)超结构的组装策略,并建立了组装参数与超结构维度和有序性之间的关系。结果表明:声悬浮法对MOF颗粒分散液浓度和颗粒的单分散性包容性极强,适用于三维超结构的自组装;点滴法对MOF颗粒分散液浓度和颗粒的单分散性有较高的要求,能组装出大面积二维MOF单层膜。该研究为利用各向异性微粒组装多维超结构提供了新的策略。

气体雾化过程中涉及颗粒形貌和空心颗粒形成的金属液滴变形和破碎数值模拟

采用考虑液滴冷却和凝固的流体体积(VOF)方法模拟金属液滴在气体雾化过程中的变形和破碎。建立典型粉末形貌和液滴破碎行为之间的相关性,以指导球形粉末颗粒的制备。结果显示,当增加液滴的气动力与黏性力的比值时,球形颗粒的形成得到加强;然而,当减小这个比值时,预期的液滴破碎模型将被改变或仅仅只发生液滴的变形。从空心颗粒的形成和演变过程的数值模拟中观察到几种典型的情况,例如,开放的空心液膜的形成、液膜封闭、气泡的离心和气泡的脱离。通过提高气体速度或液滴温度,实现较高的非平衡拉普拉斯压力或较低的粘性力,促使气泡从液滴内部分离。

均匀金属液滴喷射微制造技术的研究现状

金属液滴喷射沉积增材制造技术是利用均匀金属液滴逐点沉积成形制件的快速成型技术。根据喷射原理可分为连续喷射和按需喷射两类。对这两种技术的喷射原理、相关特点及其在微制造领域的应用研究及发展概况进行了介绍,阐述了以压电换能器和气体压力作为驱动方式的两种均匀液滴喷射成形设备的工作原理与相关特点,提出了两种技术在喷射成形低熔点金属、高熔点金属中的关键技术。在此基础上,探讨了两种工艺的发展方向及在直接金属快速成型、电子封装、喷射沉积金属涂层以及喷射印刷电路等方面的应用,并提出了该技术的研究方向。

基于金属3D打印技术成形嵌套零件工艺研究

针对传统采用多个零件拼接而成具有悬垂嵌套结构的零件,提出了金属均匀喷射熔滴沉积"双喷头"3D打印成形工艺,开发了金属微喷熔滴沉积成形试验平台,通过对新型支撑材料的配比和成形工艺研究,实现了金属以及支撑材料成形的联动控制,成形出较高精度悬垂嵌套的金属制件,与传统成形工艺相比,具有成形周期短,制造成本低等优点,实现了此类零件的即用即打,此类零件成形提供了实现的途径与条件.

旁路耦合微束等离子弧增材制造

在分析旁路耦合电弧焊的基础上,提出了旁路耦合微束等离子弧焊(DE-MPAW)方法.该方法以微束等离子弧焊炬为主路,填充焊丝为旁路,通过可调电阻调节旁路电流大小.在不降低成形效率的基础上,减小成形件的热输入,从而有利于电弧增材制造.在此基础上开展了DE-MPAW焊接方法的初步研究.在DE-MPAW焊实验系统及测控的基础上,对比研究了不同旁路电流下DE-MPAW焊熔滴过渡情况;分析了母材热输入随旁路电流的变化规律,研究了焊缝成形的变化情况;初步开展了DE-MPAW增材制造单道多层的堆垛研究.结果表明:随着旁路电流的增大,其熔滴过渡频率、母材热输入、熔深都相应地减小,且DE-MPAW方法能够较好适用于增材制造.

铝合金脉冲MIG焊接熔滴过渡行为的声发射信号时频域表征

通过在线检测铝合金脉冲MIG焊接过程的结构负载声发射信号,研究熔滴过渡模式和行为的时频域表征.结果表明,熔滴过渡声发射信号波形以及熔滴过渡声发射事件的有序性和周期性可以反映脉冲MIG焊接过程熔滴过渡的稳定性和周期性.随着脉冲频率和焊接热输入的增大,熔滴过渡模式由短路过渡转变为射滴过渡,过渡熔滴体积得到逐步细化,表现出递减的声发射能量释放特征.当熔滴过渡为短路过渡模式时,熔滴过渡声发射信号的频域范围较宽,且较为集中在高频部分;当熔滴过渡为射滴过渡模式时,熔滴过渡声发射信号的频率分布范围更窄,且集中在低频部分.随着熔滴过渡模式由短路过渡模式逐渐转变为射滴过渡模式,由熔滴过渡引入的能量变化呈现出先减小再增大的趋势.

双旁路耦合电弧MIG焊熔滴过渡受力分析

针对双旁路耦合电弧熔化极惰性气体保护(Metal inert gas,MIG)焊过程,使用高速摄像采集不同旁路电流下的熔滴过渡图像,通过图像处理提取熔滴过渡数据信息,并对熔滴所受的主要作用力进行定量计算。根据计算结果对比分析不同参数下熔滴受力的动态变化情况,研究旁路电弧对熔滴过渡的促进机理。结果表明,在焊接总电流较大的情况下电磁力对双旁路耦合电弧MIG焊熔滴过渡的影响最显著,旁路电弧可以促进熔滴上弧根面积的扩展和熔滴缩颈的形成,通过增加向下的电磁力来促进熔滴过渡,且旁路电流越大旁路电弧对熔滴过渡的促进作用越明显;在焊接总电流不变的情况下,随着旁路电流的增加熔滴过渡频率随之增加,熔滴尺寸随之减小,熔滴过渡形式逐渐由大滴过渡转变为喷射过渡。

金属微滴产生系统的设计与实现

微滴沉积制造过程中,微滴产生是一个随机变化过程。为了精确控制微滴的产生,利用现场采集的关键参量反馈控制,建立一个闭环的金属微滴产生系统。采用模块化结构设计该系统,并采用虚拟仪器技术实现了关键参量的有效控制。试验结果表明,该系统能够通过调整激振频率有效地提高微滴尺寸精度与形状精度。在优化激振频率的条件下,系统能产生具有窄带尺寸分布的金属颗粒,其直径相对偏差小于3%,满足制造过程对微滴的要求,为后续微小型金属件的成形提供必要的基础。