Modelling of Turbulent Transport in Laser Melt Pools

Author(s):  
Nilanjan Chakraborty ◽  
Suman Chakraborty

In this paper, we present a modified k-ε model capable of addressing turbulent molten metal-pool convection in the presence of a continuously evolving phase-change interface during a laser melting process. The phase change aspects of the present problem are addressed using a modified enthalpy-porosity technique. The k-ε model is suitably modified to account for the morphology of the solid-liquid interface. A three-dimensional mathematical model is subsequently utilised to simulate a typical laser melting process with high power, where effects of turbulent transport can actually be realised. In order to investigate these effects on laser molten pool convection, simulations with laminar transport and turbulent transport are carried out for same problem parameters. Finally, results of the simulation using the present turbulence model are compared with the results of laminar simulation with same problem parameters. Significant effects of turbulent transport on penetration and the geometrical features of the molten pool are observed which is an outcome of the thermal history of the pool. The thermal history in turn determines the microstructure of the work piece, which finally governs the mechanical properties of the work piece.

2003 ◽  
Author(s):  
Nilanjan Chakraborty ◽  
Dipankar Chatterjee ◽  
Suman Chakraborty

In this paper, we present a modified k-ε model capable of addressing turbulent molten metal-pool convection in the presence of a continuously evolving phase-change interface during a laser surface alloying process. The phase change aspects of the present problem are addressed using a modified enthalpy-porosity technique. The k-ε model is suitably modified to account for the morphology of the solid-liquid interface. A mathematical model is subsequently utilized to simulate a typical laser alloying process with high power, where effects of turbulent transport can actually be realized. The three-dimensional model is able to predict the species concentration distribution inside the molten pool during alloying, as well as in the entire cross section of the solidified alloy. In order to investigate these effects, the turbulent simulation results are compared with those with laminar transport for same problem parameters. Significant effects of turbulent transport on penetration and the geometrical features of the molten pool are observed which is an outcome of the thermal history of the pool. The thermal history in turn determines the microstructure of the work piece, which finally governs the mechanical properties of the work piece.


2018 ◽  
Vol 941 ◽  
pp. 1437-1442
Author(s):  
Takashi Maeshima ◽  
Keiichiro Oh-Ishi ◽  
Hiroaki Kadoura ◽  
Masashi Hara

Multi-scale microstructure observation and three dimensional finite element thermal analysis of AlSi10Mg alloy fabricated by selective laser melting (SLM) process were demonstrated in order to understand the microstructure formation process during SLM fabrication. The unique hierarchically microstructures were observed: (1) the “fish scale” microstructure corresponding to a part of molten pool consists of columnar and equiaxed grains and (2) these grains contain a substructure of α-Al surrounded by Si particles. It is revealed that a supersaturated Si concentration due to the predicted rapid cooling rate on the order of 106 oC/s. In addition, the base temperature during the fabrication increases gradually with some peak temperature of each laser path as the laser scan has proceeded on a powder layer. Although the thermal changes cause no melting of the AlSi10Mg except directly fused region by selective laser so called molten pool, those are capable of causing precipitation and/or clustering.


Author(s):  
C. H. Fu ◽  
Y. B. Guo

Selective laser melting (SLM) is widely used in making three-dimensional functional parts layer by layer. Temperature magnitude and history during SLM directly determine the molten pool dimensions and surface integrity. However, due to the transient nature and small size of the molten pool, the temperature gradient and the molten pool size are challenging to measure and control. A three-dimensional finite element (FE) simulation model has been developed to simulate multilayer deposition of Ti-6Al-4 V in SLM. A physics-based layer buildup approach coupled with a surface moving heat flux was incorporated into the modeling process. The melting pool shape and dimensions were predicted and experimentally validated. Temperature gradient and thermal history in the multilayer buildup process was also obtained. Furthermore, the influences of process parameters and materials on the melting process were evaluated.


Author(s):  
Horacio Ramos-Aboites ◽  
Abel Hernandez-Guerrero ◽  
Salvador M. Aceves ◽  
Raul Lesso-Arroyo

This paper presents the results of a -numerical transient model for phase change in a storage cell filled with a phase change material (PCM). Phase change occurs under the presence of natural convection. The PCM is encapsulated in a cylindrical energy storage cell. Two cases of PCM melting are analyzed, (1) the surface temperature of the bottom half of the cylindrical cell is kept at a constant temperature, which is higher than the melting temperature of the PCM, and (2) a fluid flows under the cell with an inlet temperature that is higher than the melting point of the PCM. The results show the evolution of the solid-liquid interface, isotherms and flow lines during the melting process.


Author(s):  
Xin Li ◽  
Ikken Sato ◽  
Akifumi Yamaji ◽  
Guangtao Duan

Molten corium-concrete interaction (MCCI) is an important ex-vessel phenomenon that could happen during the late phase of a hypothetical severe accident in a light water reactor. When the molten corium, which is generally comprised of UO2, ZrO2 and metals such as zircalloy and stainless steel, is discharged into a dry reactor cavity, a stratified molten pool configuration with two immiscible oxidic and metallic phases can be expected to form and lead to MCCI. Compared to a homogenous oxidic molten pool configuration, the metallic phase in the stratified molten pool might influence the crust formation on the corium-concrete interface and consequently cause different concrete ablation behavior to evaluate MCCI progression concerning containment failure. In terms of this issue, past experimental studies, such as COMET-L, VULCANO VBS and MOCKA test series, have been carried out to investigate the influence of such oxidic and metallic stratified pool configuration on MCCI. The experimental results have shown that the metallic phase can have a significant impact on the axial and radial ablation kinetics that could influence the ablation patterns of reactor pit. As regards numerical studies, past numerical modeling of MCCI was generally based on Eulerian methods and simplified empirical approach to simulate solid/liquid phase change and evolving of corium/crust/concrete interface. Such modeling might be efficient but have shown deficiencies and inadequacies due to its Eulerian and empirical nature, which has suggested a necessity to seek for a more mechanistic approach for modeling of MCCI. In this sense, Moving Particle Semi-implicit (MPS) method is considered suitable for MCCI analysis for its advantages of tracking interfaces and modeling phase change accurately as a Lagrangian particle method. In the present study, a three-dimensional (3-D) numerical study has been performed to simulate COMET-L3 test carried out by KIT with a stratified molten pool configuration of simulant materials with improved MPS method. Solid/liquid phase change was simulated with types of solid and liquid particles with thermal and physical properties including temperature and solid fraction, which enabled tracking of the solid/liquid status of each particle to achieve accurate free surface and corium/crust/concrete interface capturing. The heat transfer between corium/crust/concrete was modeled with heat conduction between particles. Moreover, the potential influence of the siliceous aggregates was also investigated by setting up two different case studies since there was previous study indicating that siliceous aggregates in siliceous concrete might contribute to different axial and radial concrete ablation rates. The simulation results have indicated that metal melt as corium in MCCI can have completely different characteristics regarding concrete ablation pattern from that of oxidic corium, which needs to be taken into consideration when assessing the containment melt-through time in severe accident management.


2018 ◽  
Vol 7 (4.5) ◽  
pp. 587
Author(s):  
Jay R. Patel ◽  
Manish K. Rathod

Latent heat energy storage using macro encapsulated phase change material is an emerging technique for thermal energy storage applica- tions. The main aim of the present investigation is to investigate the melting process of phase change material filled in different shaped configurations. The selected different cavities are square, circular and triangular. A mathematical model based on convection dominated melting is required to be developed, especially in view of the complex flow geometries encountered in such problems. Thus, an attempt has been made to develop a model using ANSYS Fluent 16.2 to investigate the heat transfer rate and solid-liquid interface visualization of PCM filled in different shapes of cavity. It is found that triangular shaped macro encapsulated PCM melts faster than square and circu- lar shaped encapsulated PCM.   


2020 ◽  
Vol 978 ◽  
pp. 114-120
Author(s):  
Siladitya Sukumar ◽  
Satya Prakash Kar

Single pulsed laser melting in a cylindrical titanium alloy work piece is studied numerically using an axisymmetric model. Finite volume method and Tri-Diagonal Matrix Algorithm (TDMA) are used for discretization of the energy equation and solving the resulting algebraic equation respectively in order to obtain temperature distribution inside the computational domain. Heat losses from the irradiated surface takes place through convection and radiation and other surfaces are kept insulated. A volumetric and Gaussian laser is irradiated on the work piece. Validation of the present model with the existing literature is done first and the results agree very well. Then, the detailed transport phenomena during the laser melting process is studied using the model. The enthalpy porosity technique is used track the melt pool shape and size. The role of natural convection and Marangoni convection in controlling the shape of melt pool is discussed. Maximum temperature results at domain centre and it then decreases exponentially along the axial and radial direction of the work piece because of Gaussian nature of the pulse. The numerical results obtained can provide the direction to develop models for all type of laser applications used in the industry.


2004 ◽  
Vol 127 (3) ◽  
pp. 484-491 ◽  
Author(s):  
Jing Shi ◽  
C. Richard Liu

A material softening model based on thermal activation energy has been successfully established through tempering experiments in the first part of this study. To apply the model to predicting material softening in hard turned surfaces, the thermal history of work material is needed. In this part, a three-dimensional finite element (FE) model of machining hardened 52100 steel is constructed, and coupled thermal-stress analysis is performed to obtain the material thermal history. Then the material softening model uses the computed thermal history as input to predict the material hardness profiles along the depth into the machined surfaces. Overall, the prediction precisely catches the trend of hardness change along depth and agrees reasonably well with the hardness measurement. What’s more, the sensitivity of material softening to cutting parameters is investigated both quantitatively and qualitatively. Within the investigation range, it is observed that the increase of tool flank wear and feed rate produces severe material softening and a deeper softened layer, while the increase of cutting speed causes significant softening to the surface material but hardly changes the softened depth.


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