scholarly journals Stereolithographic Additive Manufacturing of Zirconia Electrodes with Dendritic Patterns for Aluminum Smelting

2021 ◽  
Vol 11 (17) ◽  
pp. 8168
Author(s):  
Masaya Takahashi ◽  
Soshu Kirihara
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Uv Laser ◽  
Spatial Profile ◽  
Molten Salt Electrolysis ◽  
3D Objects ◽  
Photosensitive Resin ◽  
Aluminum Smelting ◽  
Computational Fluid Dynamics Cfd ◽  
Dendritic Structures

Zirconia electrodes with dendritic patterns were fabricated by stereolithographic additive manufacturing (STL-AM). A solid electrolyte of yttria-stabilized zirconia (YSZ) was selected for oxygen separation in the molten salt electrolysis of aluminum smelting without carbon dioxide excretion. Thereafter, 4, 6, 8 and 12-coordinated dendritic structures composed of cylindrical lattices were designed as computer graphics. The specific surface area of each structure was maximized by changing the aspect ratio. The spatial profile and surface pressure of the hot liquid propagation in the dendrite patterns were systematically visualized by computational fluid dynamics (CFD). During the fabrication process, a photosensitive resin containing zirconia particles was spread on a substrate, and an ultraviolet (UV) laser beam was scanned to create a two-dimensional (2D) cross-section. Through layer laminations, three-dimensional (3D) objects with dendritic structures were successfully fabricated. The ceramics were obtained through dewaxing and sintering.

Welding Technology in Additive Manufacturing Processes of 3D Objects

2017 ◽  
Vol 906 ◽  
pp. 121-130 ◽  
Author(s):  
V. Korzhyk ◽  
V. Khaskin ◽  
O. Voitenko ◽  
Volodymyr Sydorets ◽  
O. Dolianovskaia
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Simultaneous Increase ◽  
Manufacturing Cost ◽  
Three Dimensional Objects ◽  
3D Objects ◽  
Input Quality ◽  
Welding Technology ◽  
Metal Volume ◽  
Increase In Productivity

Using of welding technologies to produce metal volume objects allows considerable lowering of their manufacturing cost at simultaneous increase in productivity, compared to SLS-and SLM-processes. The most perspective welding technology of additive manufacturing of three-dimensional objects is plasma-arc technology with application of wires or powders. It allows creating at comparatively low heat input quality volumetric products with wall thickness from 3 to 50 mm from alloys based on Fe, Ni, Co, Cu, Ti, Al, as well as composite materials, containing refractory components.

scholarly journals Design and Development of Plastic Filament Extruder for 3D Printing

2018 ◽  
Vol 10 (3) ◽  
pp. 23 ◽  
Author(s):  
Mamta H. Wankhade ◽  
Satish G. Bahaley
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Three Dimensional ◽  
3D Printer ◽  
3D Objects ◽  
Fused Deposition ◽  
Additive Manufacturing Technology ◽  
Mechanized Method ◽  
Dimensional Object ◽  
The Cost

<p>3D printing is a form of additive manufacturing technology where a three dimensional object is created by laying down successive layers of material. It is mechanized method whereby 3D objects are quickly made on a reasonably sized machine connected to a computer containing blueprints for the object. As 3D printing is growing fast and giving a boost to product development, the factories doing 3D printing need to continuously meet the printing requirements and maintain an adequate amount of inventory of the filament. As the manufactures have to buy these filaments from various vendors, the cost of 3D printing increases. To overcome the problem faced by the manufacturers, small workshop owners, the need of 3D filament making machine arises. This project focuses on designing and fabricating a portable fused deposition 3D printer filament making machine with cheap and easily available components to draw 1.75 mm diameter ABS filament.</p>

scholarly journals A New Approach to Micromachining: High-Precision and Innovative Additive Manufacturing Solutions Based on Photopolymerization Technology

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2951 ◽  
Author(s):  
Paweł Fiedor ◽  
Joanna Ortyl
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Liquid Crystal Display ◽  
Three Dimensional ◽  
Digital Light Processing ◽  
3D Objects ◽  
Conscious Choice ◽  
Optical Applications ◽  
Manufacturing Technologies ◽  
Printing Processes

The following article introduces technologies that build three dimensional (3D) objects by adding layer-upon-layer of material, also called additive manufacturing technologies. Furthermore, most important features supporting the conscious choice of 3D printing methods for applications in micro and nanomanufacturing are covered. The micromanufacturing method covers photopolymerization-based methods such as stereolithography (SLA), digital light processing (DLP), the liquid crystal display–DLP coupled method, two-photon polymerization (TPP), and inkjet-based methods. Functional photocurable materials, with magnetic, conductive, or specific optical applications in the 3D printing processes are also reviewed.

scholarly journals Phase-field modeling of grain evolutions in additive manufacturing from nucleation, growth, to coarsening

2021 ◽  
Vol 7 (1) ◽  
Author(s):  
Min Yang ◽  
Lu Wang ◽  
Wentao Yan
Keyword(s):  
Additive Manufacturing ◽  
Phase Field ◽  
Field Model ◽  
Three Dimensional ◽  
Phase Field Model ◽  
Nucleation Theory ◽  
Experimental Result ◽  
Classical Nucleation Theory ◽  
Validation Experiment ◽  
Powder Particles

AbstractA three-dimensional phase-field model is developed to simulate grain evolutions during powder-bed-fusion (PBF) additive manufacturing, while the physically-informed temperature profile is implemented from a thermal-fluid flow model. The phase-field model incorporates a nucleation model based on classical nucleation theory, as well as the initial grain structures of powder particles and substrate. The grain evolutions during the three-layer three-track PBF process are comprehensively reproduced, including grain nucleation and growth in molten pools, epitaxial growth from powder particles, substrate and previous tracks, grain re-melting and re-growth in overlapping zones, and grain coarsening in heat-affected zones. A validation experiment has been carried out, showing that the simulation results are consistent with the experimental results in the molten pool and grain morphologies. Furthermore, the grain refinement by adding nanoparticles is preliminarily reproduced and compared against the experimental result in literature.

scholarly journals Efficient 3D printing via photooxidation of ketocoumarin based photopolymerization

2021 ◽  
Vol 12 (1) ◽  
Author(s):  
Xiaoyu Zhao ◽  
Ye Zhao ◽  
Ming-De Li ◽  
Zhong’an Li ◽  
Haiyan Peng ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Visible Light ◽  
Light Exposure ◽  
Three Dimensional ◽  
3D Printer ◽  
Light Penetration ◽  
Viable Solution

AbstractPhotopolymerization-based three-dimensional (3D) printing can enable customized manufacturing that is difficult to achieve through other traditional means. Nevertheless, it remains challenging to achieve efficient 3D printing due to the compromise between print speed and resolution. Herein, we report an efficient 3D printing approach based on the photooxidation of ketocoumarin that functions as the photosensitizer during photopolymerization, which can simultaneously deliver high print speed (5.1 cm h−1) and high print resolution (23 μm) on a common 3D printer. Mechanistically, the initiating radical and deethylated ketocoumarin are both generated upon visible light exposure, with the former giving rise to rapid photopolymerization and high print speed while the latter ensuring high print resolution by confining the light penetration. By comparison, the printed feature is hard to identify when the ketocoumarin encounters photoreduction due to the increased lateral photopolymerization. The proposed approach here provides a viable solution towards efficient additive manufacturing by controlling the photoreaction of photosensitizers during photopolymerization.

scholarly journals A Review on Additive Manufacturing Possibilities for Electrical Machines

Energies ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1940
Author(s):  
Muhammad Usman Naseer ◽  
Ants Kallaste ◽  
Bilal Asad ◽  
Toomas Vaimann ◽  
Anton Rassõlkin
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Three Dimensional ◽  
Electrical Machines ◽  
Electromagnetic Properties ◽  
Scale Production ◽  
Performance Parameters ◽  
Large Scale Production ◽  
One Step ◽  
Manufacturing Techniques

This paper presents current research trends and prospects of utilizing additive manufacturing (AM) techniques to manufacture electrical machines. Modern-day machine applications require extraordinary performance parameters such as high power-density, integrated functionalities, improved thermal, mechanical & electromagnetic properties. AM offers a higher degree of design flexibility to achieve these performance parameters, which is impossible to realize through conventional manufacturing techniques. AM has a lot to offer in every aspect of machine fabrication, such that from size/weight reduction to the realization of complex geometric designs. However, some practical limitations of existing AM techniques restrict their utilization in large scale production industry. The introduction of three-dimensional asymmetry in machine design is an aspect that can be exploited most with the prevalent level of research in AM. In order to take one step further towards the enablement of large-scale production of AM-built electrical machines, this paper also discusses some machine types which can best utilize existing developments in the field of AM.

scholarly journals The Study of Carbon Recovery from Electrolysis Aluminum Carbon Dust by Froth Flotation

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 145
Author(s):  
Hesong Li ◽  
Jiaoru Wang ◽  
Wenyuan Hou ◽  
Mao Li ◽  
Benjun Cheng ◽  
...  
Keyword(s):  
Particle Size ◽  
Particle Size Distribution ◽  
Size Distribution ◽  
Mixing Time ◽  
Froth Flotation ◽  
Aluminum Electrolysis ◽  
Carbon Powder ◽  
Molten Salt Electrolysis ◽  
Carbon Recovery ◽  
Aluminum Smelting

A large amount of carbon dust is generated in the process of aluminum smelting by molten salt electrolysis. The carbon dust is solid hazardous waste but contains a large quantity of recyclable components such as carbon and fluoride. How to recycle carbon dust more effectively is a challenge in the aluminum electrolysis field. In this study, X-ray diffraction, scanning electron microscope, and other methods were used to analyze the phase composition of electrolytic aluminum carbon dust. The effects of particle size distribution of carbon dust, impeller speed, reagent addition, mixing time, and flotation time on the flotation recovery of carbon dust were studied. The optimal flotation conditions were obtained and the flotation products were analyzed. The results show that the optimal particle size distribution is 70% of particles below 200 mesh, corresponding to a grinding time of 11 min. The optimum speed of the flotation machine was to be between 1600 and 1800 r/min with the best slurry concentration of 20–30% and 5 min mixing time, and the collector kerosene was suitable for adding in batches. Under the above conditions, the recovered carbon powder with a carbon content of 75.6% was obtained, and the carbon recovery rate was 86.9%.

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

Assessment of Unsteady Flows in Turbines

1992 ◽  
Vol 114 (1) ◽  
pp. 79-90 ◽  
Author(s):  
O. P. Sharma ◽  
G. F. Pickett ◽  
R. H. Ni
Keyword(s):  
Unsteady Flow ◽  
Three Dimensional ◽  
Flow Simulation ◽  
Experimental Investigations ◽  
Flow Parameters ◽  
Research Activities ◽  
Flow Features ◽  
Computational Fluid Dynamics Cfd ◽  
Turbine Design ◽  
The Impact

The impacts of unsteady flow research activities on flow simulation methods used in the turbine design process are assessed. Results from experimental investigations that identify the impact of periodic unsteadiness on the time-averaged flows in turbines and results from numerical simulations obtained by using three-dimensional unsteady Computational Fluid Dynamics (CFD) codes indicate that some of the unsteady flow features can be fairly accurately predicted. Flow parameters that can be modeled with existing steady CFD codes are distinguished from those that require unsteady codes.

The Effect of Bench Arrangements on the Natural Ventilation of a Multispan Greenhouse

2013 ◽  
Author(s):  
Sunita Kruger ◽  
Leon Pretorius
Keyword(s):  
Fluid Dynamics ◽  
Natural Ventilation ◽  
Three Dimensional ◽  
Two Dimensional ◽  
Low Velocity ◽  
Lower Velocity ◽  
Cfd Models ◽  
Temperature Distributions ◽  
Computational Fluid Dynamics Cfd ◽  
Plant Level

In this paper, the influence of various bench arrangements on the microclimate inside a two-span greenhouse is numerically investigated using three-dimensional Computational Fluid Dynamics (CFD) models. Longitudinal and peninsular arrangements are investigated for both leeward and windward opened roof ventilators. The velocity and temperature distributions at plant level (1m) were of particular interest. The research in this paper is an extension of two-dimensional work conducted previously [1]. Results indicate that bench layouts inside the greenhouse have a significant effect on the microclimate at plant level. It was found that vent opening direction (leeward or windward) influences the velocity and temperature distributions at plant level noticeably. Results also indicated that in general, the leeward facing greenhouses containing either type of bench arrangement exhibit a lower velocity distribution at plant level compared to windward facing greenhouses. The latter type of greenhouses has regions with relatively high velocities at plant level which could cause some concern. The scalar plots indicate that more stagnant areas of low velocity appear for the leeward facing greenhouses. The windward facing greenhouses also display more heterogeneity at plant level as far as temperature is concerned.

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