scholarly journals Transient Powder Melting in SLM Using an Analytical Model with Phase Change and Spherical Symmetry in a Semi-Infinite Medium

2019 ◽  
Vol 3 (2) ◽  
pp. 50
Author(s):  
Marios M. Fyrillas ◽  
Loucas Papadakis
Keyword(s):  
Heat Transfer ◽  
Heat Source ◽  
Phase Change ◽  
Square Root ◽  
Spherical Coordinates ◽  
Laser Melting ◽  
Finite Radius ◽  
Element Analysis ◽  
Analytical Expression ◽  
Melt Pool

In this work, we introduce an analytical expression for approximating the transient melting radius during powder melting in Selective Laser Melting (SLM) assumed with a stationary laser heat source. The purpose of this work is to evaluate the suggested analytical approach in determining the melt pool geometry during laser processing, by considering heat transfer and phase change effects. This will allow for the rendering of the first findings on the way to a quasi-real time calculation of the melt pool during laser melting, which will contribute significantly to the process design and control, especially when new powders are applied. Initially, we consider the heat transfer process associated with a point heat source, releasing a continuous and constant power (in a semi-infinite powder bed. On the point of the heat source the temperature is infinite, and the material starts to melt spherically outwards, creating an interface that separates the solid from the molten material; we assume different properties between the two phases. Unlike the cases of the cartesian and cylindrical coordinates, (in a cartesian coordinate the heat source is over a plane, i.e., W/m2, and in cylindrical along a line, i.e., W/m), where the melting process is proportional to the square root of time, in spherical coordinates the melting stops at a finite radius, i.e., a maximum radius, which depends only on the heat source, the conductivity of the solid and the difference between the far-field temperature and the melting temperature of the material. Here we should also point out that to achieve continuous melting in spherical coordinates the power of the source must increase with the square root of the time. The obtained analytical expression for the maximum melting radius and the approximate expression for its dependence on the time compare well with the numerical results obtained by a finite element analysis.

scholarly journals Phase Change with Density Variation and Cylindrical Symmetry: Application to Selective Laser Melting

2019 ◽  
Vol 3 (3) ◽  
pp. 62 ◽  
Author(s):  
Fyrillas ◽  
Ioannou ◽  
Papadakis ◽  
Rebholz ◽  
Doumanidis
Keyword(s):  
Heat Transfer ◽  
Heat Source ◽  
Phase Change ◽  
Selective Laser Melting ◽  
Unit Length ◽  
Cylindrical Symmetry ◽  
Density Variation ◽  
Laser Melting ◽  
Molten Material ◽  
Melt Pool

In this paper we introduce an analytical approach for predicting the melting radius during powder melting in selective laser melting (SLM) with minimum computation duration. The purpose of this work is to evaluate the suggested analytical expression in determining the melt pool geometry for SLM processes, by considering heat transfer and phase change effects with density variation and cylindrical symmetry. This allows for rendering first findings of the melt pool numerical prediction during SLM using a quasi-real-time calculation, which will contribute significantly in the process design and control, especially when applying novel powders. We consider the heat transfer problem associated with a heat source of power Q' (W/m) per unit length, activated along the span of a semi-infinite fusible material. As soon as the line heat source is activated, melting commences along the line of the heat source and propagates cylindrically outwards. The temperature field is also cylindrically symmetric. At small times (i.e., neglecting gravity and Marangoni effects), when the density of the solid material is less than that of the molten material (i.e., in the case of metallic powders), an annulus is created of which the outer interface separates the molten material from the solid. In this work we include the effect of convection on the melting process, which is shown to be relatively important. We also justify that the assumption of constant but different properties between the two material phases (liquid and solid) does not introduce significant errors in the calculations. A more important result; however, is that, if we assume constant energy input per unit length, there is an optimum power of the heat source that would result to a maximum amount of molten material when the heat source is deactivated. The model described above can be suitably applied in the case of selective laser melting (SLM) when one considers the heat energy transferred to the metallic powder bed during scanning. Using a characteristic time and length for the process, we can model the energy transfer by the laser as a heat source per unit length. The model was applied in a set of five experimental data, and it was demonstrated that it has the potential to quantitatively describe the SLM process.

A Comparative Study Between Selective Laser Melting and Electron Beam Additive Manufacturing Based on Thermal Modeling

2018 ◽  
Author(s):  
M. Shafiqur Rahman ◽  
Paul J. Schilling ◽  
Paul D. Herrington ◽  
Uttam K. Chakravarty
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Heat Source ◽  
Selective Laser Melting ◽  
Thermal Modeling ◽  
Maximum Temperature ◽  
Full Density ◽  
Rate Variation ◽  
Laser Melting ◽  
Melt Pool

Selective Laser Melting (SLM) and Electron Beam Additive Manufacturing (EBAM) are two of the most promising additive manufacturing technologies that can make full density metallic components using layer-by-layer fabrication methods. In this study, three-dimensional computational fluid dynamics models with Ti-6Al-4V powder were developed to conduct numerical simulations of both the SLM and EBAM processes. A moving conical volumetric heat source with Gaussian distribution and temperature-dependent thermal properties were incorporated in the thermal modeling of both processes. The melt-pool geometry and its thermal behavior were investigated numerically and results for temperature profile, cooling rate, variation in specific heat, density, thermal conductivity, and enthalpy were obtained with similar heat source specifications. Results obtained from the two models at the same maximum temperature of the melt pool were then compared to describe their deterministic features to be considered for industrial applications. Validation of the modeling was performed by comparing the EBAM simulation results with the EBAM experimental results for melt pool geometry.

Numerical Survey of the Melting Driven Natural Convection Using Generation Heat Source: Application to the Passive Cooling of Electronics Using Nano-Enhanced Phase Change Material

2019 ◽  
Vol 12 (2) ◽  
Author(s):  
Hamza Faraji ◽  
Mustapha Faraji ◽  
Mustapha El Alami
Keyword(s):  
Heat Transfer ◽  
Natural Convection ◽  
Heat Source ◽  
Phase Change ◽  
Phase Change Material ◽  
Metallic Nanoparticles ◽  
Simple Algorithm ◽  
Bottom Side ◽  
Volume Method ◽  
Change Material

Abstract The present paper reports numerical results of the melting driven natural convection in an inclined rectangular enclosure filled with nano-enhanced phase change material (NePCM). The enclosure is heated from the bottom side by a flush-mounted heat source (microprocessor) that generates heat at a constant and uniform volumetric rate and mounted on a substrate (motherboard). All the walls are considered adiabatic. The purpose of the investigation is analyzing the effect of nanoparticles insertion by quantifying their contribution to the overall heat transfer. Combined effects of the PCM type, the inclination angle and the nanoparticles fraction on the structure of the fluid flow and heat transfer are investigated. A 2D mathematical model based on the conservation equations of mass, momentum, and energy was developed. The governing equations were integrated and discretized using the finite volume method. The SIMPLE algorithm was adopted for velocity–pressure coupling. The obtained results show that the nanoparticles insertion has an important quantitative effect on the overall heat transfer. The insertion of metallic nanoparticles with different concentrations affects the thermal behavior of the heat sink. They contribute to an efficient cooling of the heat source. The effect of nanoparticles insertion is also shown at the temperature distribution along the substrate.

Heat Transfer and Interface Motion During Melting and Solidification around a Finned Heat Source/Sink

1981 ◽  
Vol 103 (4) ◽  
pp. 720-726 ◽  
Author(s):  
A. G. Bathelt ◽  
R. Viskanta
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Heat Source ◽  
Phase Change ◽  
Source Surface ◽  
Transfer Coefficients ◽  
Interface Motion ◽  
Source Sink ◽  
Phase Change Heat Transfer ◽  
Solid Liquid

The effectiveness of extended surfaces on a horizontal, cylindrical heat source/sink was studied experimentally during solid-liquid phase change heat transfer. Melting and freezing experiments were performed in a test cell suitable for photographic and shadowgraphic observations using a circular cylinder with three rectangular fins parallel to the axis and evenly distributed around the circumference of the heat exchanger. Results are reported for n-heptadecane as the phase change material. Orientation of fins on the heat exchanger with respect to the gravitational field are found to have more influence on the melting than on the freezing processes. The use of fins was found to be more effective for melting than for freezing. The instantaneous local and circumferentially averaged heat transfer coefficients at the heat source surface for melting from a cylinder with fins were usually within ±20 percent of those for melting from a bare cylinder. During solidification the degree of heat transfer enhancement due to finning is greatest when the frozen layer is thin and decreases as the layer grows thicker.

Numerical Evaluation of Multiple Phase Change Materials for Pulsed Electronics Applications

2016 ◽  
Author(s):  
David Gonzalez-Nino ◽  
Lauren M. Boteler ◽  
Dimeji Ibitayo ◽  
Nicholas R. Jankowski ◽  
Pedro O. Quintero
Keyword(s):  
Heat Transfer ◽  
Thermal Conductivity ◽  
Heat Source ◽  
Phase Change ◽  
Phase Change Materials ◽  
High Energy ◽  
Heat Of Fusion ◽  
Maximum Temperature ◽  
Conductivity Enhancement ◽  
Fast Transient

A simple and easy to implement 1-D heat transfer modeling approach is presented in order to investigate the performance of various phase change materials (PCMs) under fast transient thermal loads. Three metallic (gallium, indium, and Bi/Pb/Sn/In alloy) and two organic (erythritol and n-octadecane) PCMs were used for comparison. A finite-difference method was used to model the transient heat transfer through the system while a heat integration or post-iterative method was used to model the phase change. To improve accuracy, the material properties were adjusted at each iteration depending on the state of matter of the PCM. The model assumed that the PCM was in direct contact with the heat source, located on the top of the chip, without the presence of a thermal conductivity enhancement. Results show that the three metallic PCMs outperform organic PCMs during fast transient pulses in spite of the fact that two of the metallic PCMs (i.e. indium and Bi/Pb/Sn/In) have considerably lower volumetric heats of fusion than erythritol. This is due to the significantly higher thermal conductivity values of metals which allow faster absorption of the heat energy by the PCM, a critical need in high-energy short pulses. The most outstanding case studied in this paper, Bi/Pb/Sn/In having only 52% of erythritol’s heat of fusion, showed a maximum temperature 20°C lower than erythritol during a 32 J and 0.02 second pulse. This study has shown thermal buffering benefits by using a metallic PCM directly in contact with the heat source during short transient heat loads.

NATURAL CONVECTION HEAT TRANSFER FROM A DISCRETE HEAT SOURCE COUPLED WITH CONDUCTION DOMINATED PHASE CHANGE

1998 ◽  
Vol 22 (3) ◽  
pp. 269-289
Author(s):  
M. Lacroix
Keyword(s):  
Heat Transfer ◽  
Thermal Conductivity ◽  
Steady State ◽  
Natural Convection ◽  
Thermal Diffusivity ◽  
Heat Source ◽  
Phase Change ◽  
Numerical Study ◽  
Thermal Conductivity Ratio ◽  
Discrete Heat Source

A numerical study has been conducted for the heat transfer from a discrete heat source by natural convection in air above coupled with conduction dominated melting of a phase change material (PCM) below via a wall of finite thermal diffusivity. Results indicate that the presence of a PCM layer underneath the wall significantly delays the temperature rise of the heat source. The time delay increases as the thermal diffusivity of the wail material decreases and as the thickness of the PCM layer increases. For high thermal conductivity wall materials [Formula: see text] the steady state heat source temperatures are similar and independent of the PCM layer. On the other hand, for [Formula: see text], the steady state temperatures are higher and dependent on the thickness of the PCM layer. A correlation is proposed in terms of the thickness of the PCM layer and the thermal conductivity ratio of the wall.

Finite Element Thermal Analysis of Melt Pool in Selective Laser Melting Process

2018 ◽  
Author(s):  
Zhibo Luo ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Heat Source ◽  
Selective Laser Melting ◽  
Computational Cost ◽  
Melting Process ◽  
Point Heat Source ◽  
Laser Melting ◽  
Line Heat Source ◽  
Powder Bed ◽  
Melt Pool ◽  
Gaussian Point

Selective laser melting is one of the powder bed fusion processes which fabricates a part through layer-wised method. Due to the ability to build a customized and complex part, selective laser melting process has been broadly studied in academic and applied in industry. However, rapidly changed thermal cycles and extremely high-temperature gradients among the melt pool induce a periodically changed thermal stress in solidified layers and finally result in a distorted part. Therefore, the temperature distribution in the melt pool and the size and shape of the melt pool directly determine the mechanical and geometrical property of final part. As experimental trial-and-error method takes a huge amount of cost, different numerical methods have been adopted to estimate the transient temperature and thermal stress distribution in the melt pool and powder bed. The most existing research utilizes the moving Gaussian point heat source to model the profile of the melt pool, which consumes a significant amount of computational cost and cannot be used to implement the part-level simulation. This research proposes a new line heat source to replace the moving point heat source. Some efforts are applied to reduce the computational cost. Specifically, a relatively large step size is used for the line heat source to reduce the number of time steps. In addition, a mesh refinement scheme is adopted to reduce the number of cells in each time step by refining the mesh close to the heat source and coarsening the mesh far away from it. On the other hand, efforts are implemented to increase the accuracy of the simulation result. Temperature-dependent material properties are considered in this FE framework. In addition, material transition among powder, liquid, and solid are incorporated in the developed FE framework. In this study, temperature simulation of one scanning track based on self-developed FE code is applied for Stainless Steel 316L. The simulation results show that the temperature distribution and history of melt pool within line heat source are comparable to that of the moving Gaussian point heat source. While the simulation time is reduced by more than two times depending on the length of line heat input. Therefore, this FE model can be used to numerically investigate the process parameters and help to control the quality of the final part.

Study of the Melting Behavior in a PCM-Based Thermal Energy Storage

2015 ◽  
Author(s):  
Mohammad Bashar ◽  
Kamran Siddiqui
Keyword(s):  
Heat Transfer ◽  
Energy Storage ◽  
Heat Source ◽  
Phase Change ◽  
Thermal Energy ◽  
Thermal Energy Storage ◽  
Storage Systems ◽  
Renewable Energy Sources ◽  
Heat Transfer Process ◽  
Convective Cells

Thermal energy storages are becoming important due to their significance in energy conservation as well as for the uninterrupted supply of thermal energy from renewable energy sources. The latent heat-based thermal energy storage systems utilizing phase change material (PCM) are gaining much attention due to some inherent advantages compared to sensible heat-based storage systems. However, the heat transfer process associated with the phase change in a PCM is complex and not well understood. In the present study, the melting process in a PCM-based thermal storage is experimentally studied. Two different configurations of the heat source were considered; horizontal and U-tube heat sources. The results show that the heat source shape has a significant influence on the solid to liquid phase change process (melting). The results also show that for the horizontal heat source configuration, the solid-liquid interface has a wavy profile, which is attributed to the convective cells in the melted domain of the PCM. These convective cells also influence the heat transfer coefficient, which decreased with an increase in the melted fraction. In U-tube configuration, the heat is non-uniformly transferred to the PCM domain.

scholarly journals Selective Laser Melting of Pre-Alloyed NiTi Powder: Single-Track Study and FE Modeling with Heat Source Calibration

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7486
Author(s):  
Stanislav V. Chernyshikhin ◽  
Denis G. Firsov ◽  
Igor V. Shishkovsky
Keyword(s):  
Heat Source ◽  
Thermal Behavior ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Laser Power ◽  
Scanning Speed ◽  
Fe Modeling ◽  
Single Track ◽  
Laser Melting ◽  
Melt Pool

Unique functional properties such as the low stiffness, superelasticity, and biocompatibility of nickel–titanium shape-memory alloys provide many applications for such materials. Selective laser melting of NiTi enables low-cost customization of devices and the manufacturing of highly complex geometries without subsequent machining. However, the technology requires optimization of process parameters in order to guarantee high mass density and to avoid deterioration of functional properties. In this work, the melt pool geometry, surface morphology, formation mode, and thermal behavior were studied. Multiple combinations of laser power and scanning speed were used for single-track preparation from pre-alloyed NiTi powder on a nitinol substrate. The experimental results show the influence of laser power and scanning speed on the depth, width, and depth-to-width aspect ratio. Additionally, a transient 3D FE model was employed to predict thermal behavior in the melt pool for different regimes. In this paper, the coefficients for a volumetric double-ellipsoid heat source were calibrated with bound optimization by a quadratic approximation algorithm, the design of experiments technique, and experimentally obtained data. The results of the simulation reveal the necessary conditions of transition from conduction to keyhole mode welding. Finally, by combining experimental and FE modeling results, the optimal SLM process parameters were evaluated as P = 77 W, V = 400 mm/s, h = 70 μm, and t = 50 μm, without printing of 3D samples.

Analysis of the Temperature Evolution during Lined Pipe Welding

2014 ◽  
Vol 1016 ◽  
pp. 753-757 ◽  
Author(s):  
Obeid Obeid ◽  
Giulio Alfano ◽  
Hamid Bahai
Keyword(s):  
Heat Transfer ◽  
Finite Element ◽  
Heat Source ◽  
Thermal History ◽  
Numerical Models ◽  
Welding Process ◽  
Gta Welding ◽  
Element Analysis ◽  
Pipe Welding ◽  
Mn Steel

A numerical analysis of thermal phenomena occurring during lined-pipe welding is presented in this paper. Numerical models of surfaces and volumetric heat sources were used to predict the time evolution of the temperature field both in a corrosion-resistance-alloy (CRA) liner, made of SUS304 stainless steel (SS), and for the single-pass girth welding of a carbon-manganese (C-Mn) steel pipe. Using the finite-element code ABAQUS, three-dimensional non-liner heat-transfer analyses was carried out to simulate the gas-tungsten-arc (GTA) welding process used in liner welding and the metal-inert-gas (MIG) welding process consumed in C-Mn steel backing welding. FORTRAN user subroutines were coded to implement the movable welding heat source and heat transfer coefficient models. The thermal history was numerically computed at locations where circumferential angles from the welding start/atop position are 90°, 180° and 270° with respect to axial distances from the weld centerline (WC). Keywords: Finite element analysis FEA, CRA Liner, C-Mn steel backing, Heat source, Thermal history.

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