Soot Volume Fraction Measurements by Auto-Compensating Laser-Induced Incandescence in Diffusion Flames Generated by Ethylene Pool Fire

The main characteristics of pool fire flames are flame height, air entrainment, pulsation of the flame, formation and properties of soot particles, mass burning rate, radiation feedback to the pool surface, and the amount of pollutants including soot released to the environment. In this type of buoyancy controlled flames, the soot content produced and their subsequent thermal radiation feedback to the pool surface are key to determine the self-sustainability of the flame, their mass burning rate and the heat release rate. The accurate characterization of these flames is an involved task, specially for modelers due to the difficulty of imposing adequate boundary conditions. For this reason, efforts are being made to design experimental campaigns with well-controlled conditions for their reliable repeatability, reproducibility and replicability. In this work, we characterized the production of soot in a surrogate pool fire. This is emulated by a bench-scale porous burner fueled with pure ethylene burning in still air. The flame stability was characterized with high temporal and spatial resolution by using a CMOS camera and a fast photodiode. The results show that the flame exhibit a time-varying propagation behavior with a periodic separation of the reactive zone. Soot volume fraction distributions were measured at nine locations along the flame centerline from 20 to 100 mm above the burner exit using the auto-compensating laser-induced incandescence (AC-LII) technique. The mean, standard deviation and probability density function of soot volume fraction were determined. Soot volume fraction presents an increasing tendency with the height above the burner, in spite of a local decrease at 90 mm which is approximately the position separating the lower and attached portion of the flame from the higher more intermittent one. The results of this work provide a valuable data set for validating soot production models in pool fire configurations.

Molten Pool Behaviors in Double-Sided Pulsed GMAW of T-Joint: A Numerical Study

The T-joint is one of the essential types of joints in aluminum welded structures. Double-sided welding is a preferable solution to maintain high efficiency and avoid significant distortion during T-joint welding. However, interactions between double-sided molten pools make flow behaviors complicated during welding. Numerical simulations regarding molten pool behaviors were conducted in this research to understand the complex flow phenomenon. The influences of wire feed rates and torch distances were simulated and discussed. The results show that droplet impinging drives the fluid to flow down to the root and form a frontward vortex. Marangoni stress forces the fluid to form an outward vortex near the molten pool boundary and flatten the concave-shaped molten pool surface. With an increased wire feed speed, the volume of the molten pool increases, and the root fusion is improved. With an increased torch distance, the width of the front molten pool decreases while the length increases, and the rear molten pool size decreases slightly. Both wire feed speeds and the torch distances have limited influences on the basic flow characteristics.

Insights into the Pollutant Removal Performance of Stormwater Green Infrastructures: A Case Study of Detention Basins and Retention Ponds

The quality of water has deteriorated due to urbanization and the occurrence of urban stormwater runoff. To solve this problem, this study investigated the pollutant reduction effects from the geometric and hydrological factors of green infrastructures (GIs) to more accurately design GI models, and evaluated the factors that are required for such a design. Among several GIs, detention basins and retention ponds were evaluated. This study chose the inflow, outflow, total suspended solids (TSS), total phosphorus (TP), watershed area, GI area (bottom area in detention basins and permanent pool surface area in retention ponds), and GI volume (in both detention basins and retention ponds) for analysis and applied both ordinary least squares (OLS) regression and multiple linear regression (MLR). The geometric factors do not vary within each GI, but there may be a bias due to the number of stormwater events. To solve this problem, three methods that involved randomly extracting data with a certain range and excluding outliers were applied to the models. The accuracies of these OLS and MLR models were analyzed through the percentage bias (PBIAS), Nash-Sutcliffe efficiency (NSE), and RMSE-observations standard deviation ratio (RSR). The results of this study suggest that models which consider the influent concentration combined with the hydrological and GI geometric parameters have better correlations than models that consider only a single parameter.

Relationship among Welding Defects with Convection and Material Flow Dynamic Considering Principal Forces in Plasma Arc Welding

The material flow dynamic and velocity distribution on the melted domain surface play a crucial role on the joint quality and formation of welding defects. In this study, authors investigated the effects of the low and high currents of plasma arc welding on the material flow and thermodynamics of molten pool and its relationship to the welding defects. The high-speed video camera (HSVC) was used to observe the convection of the melted domain and welded-joint appearance. Furthermore, to consider the Marangoni force activation, the temperature on the melted domain was measured by a thermal HSVC. The results revealed that the velocity distribution on the weld pool surface was higher than that inside the molten weld pool. Moreover, in the case of 80 A welding current, the convection speed of molten was faster than that in other cases (120 A and 160 A). The serious undercut and humping could be seen on the top surface (upper side) and unstable weld bead was visualized on the back side (bottom surface). In the case of 160 A welding current, the convection on the weld pool surface was much more complex in comparison with 80 A and 120 A cases. The excessive convex defect at the bottom side and the concave defect at the top surface were observed. In the case of 120 A welding current, two convection patterns with the main flow in the backward direction were seen. Almost no welding defect could be found. The interaction between the shear force and Marangoni force played a solid state on the convection and heat transportation processes in the plasma arc welding process.

Inverse Columnar-Equiaxed Transition (CET) in 304 and 316L Stainless Steels Melt by Electron Beam for Additive Manufacturing (AM)

According to Hunt’s columnar-to-equiaxed transition (CET) criterion, which is generally accepted, a high-temperature gradient (G) in the solidification front is preferable to a low G for forming columnar grains. Here, we report the opposite tendency found in the solidification microstructure of stainless steels partially melted by scanning electron beam for powder bed fusion (PBF)-type additive manufacturing. Equiaxed grains were observed more frequently in the region of high G rather than in the region of low G, contrary to the trend of the CET criterion. Computational thermal-fluid dynamics (CtFD) simulation has revealed that the fluid velocity is significantly higher in the case of smaller melt regions. The G on the solidification front of a small melt pool tends to be high, but at the same, the temperature gradient along the melt pool surface also tends to be high. The high melt surface temperature gradient can enhance Marangoni flow, which can apparently reverse the trend of equiaxed grain formation.

Numerical Simulation and Industrial Application of High Speed Tandem TIG Welding

Self-developed high speed tandem TIG welding equipment were adopted to manufacture titanium welded tubes with high efficiency and high quality. The joint made by this high efficient welding process met Chinese standard requirements. A coupled electrode, arc and weld pool numerical model was also developed to investigate temperature and velocity distributions, and energy propagation of this welding process. The numerical results showed that the Marangoni stress was much higher than the arc shear stress, and was mainly positive after leading and trailing arcs in the x and y directions, so the molten metal flowed backward on the top weld pool surface. Previous studies proposed that a “pull-push” flow pattern defined as a backward molten metal flow after the leading arc and a forward molten metal flow before the trailing arc existed on the top weld pool surface in tandem arc welding processes, while it was not observed in this case. The calculated arc efficiency of the high speed tandem TIG welding was about 79.8%.

Three-Dimensional Reconstruction of Welding Pool Surface by Binocular Vision

Current research of binocular vision systems mainly need to resolve the camera’s intrinsic parameters before the reconstruction of three-dimensional (3D) objects. The classical Zhang’ calibration is hardly to calculate all errors caused by perspective distortion and lens distortion. Also, the image-matching algorithm of the binocular vision system still needs to be improved to accelerate the reconstruction speed of welding pool surfaces. In this paper, a preset coordinate system was utilized for camera calibration instead of Zhang’ calibration. The binocular vision system was modified to capture images of welding pool surfaces by suppressing the strong arc interference during gas metal arc welding. Combining and improving the algorithms of speeded up robust features, binary robust invariant scalable keypoints, and KAZE, the feature information of points (i.e., RGB values, pixel coordinates) was extracted as the feature vector of the welding pool surface. Based on the characteristics of the welding images, a mismatch-elimination algorithm was developed to increase the accuracy of image-matching algorithms. The world coordinates of matching feature points were calculated to reconstruct the 3D shape of the welding pool surface. The effectiveness and accuracy of the reconstruction of welding pool surfaces were verified by experimental results. This research proposes the development of binocular vision algorithms that can reconstruct the surface of welding pools accurately to realize intelligent welding control systems in the future.

Controlling mechanisms of burning rate enhancement while using Flame Refluxer technology during in situ burning of crude oil spills

ABSTRACT The focus of this study is to quantify the controlling mechanisms, which increases the burning rate of a pool fire using a Flame RefluxerTM. Part of the Flame RefluxerTM, is exposed to the fire and is heated up transferring heat to the fuel pool layer to which it extends. This enhances the conventional heat transfer that occurs only through the pool surface by transferring the heat from a fire to an in-depth layer of the liquid. Both sensible heat and heat of vaporization are supplied at increased rates by the submerged material. As an additional important effect, nucleate boiling onsets at the surface of the inserted material that generates bubbles of fuel vapor. These bubbles are transported to the surface of the pool, where they burst and release the v0061por to the gas-phase. While doing so, additional processes such as formation of micron-sized droplets or small jets of liquid fuel from the break point occur. This phenomenon causes additional fuel in liquid phase transported to the gas-phase, where they vaporize, ignite and burn in heterogeneous mode. Therefore, the processes involved in FR occur in three steps; enhancement of heat transfer to the liquid causing nucleate boiling, formation of bubbles and their transport, and dynamics of bubble breakage at the pool surface causing transfer of liquid fuel in the form of tiny droplets or jets towards the gas-phase. This study analyzes the influence of bubbles on the burning behavior of a pool fire using a simple experiment involving burning ethanol as a fuel. Ethanol is used due to its transparency and hence bubble behavior is easily observable on the heater surface. A 5cm x 5cm glass enclosure constantly replenished with ethanol serves as the burning pool. A solid aluminum block (8.8 cm tall x 3.6 cm wide x 1.2 cm thick) is placed in the flame to act as the Flame RefluxerTM. Bubble counts and burning rate measurements indicate the influence of the bubbles on the overall burning rate of the liquid pool.

Automated Recognition of Weld Pool Characteristics from Active Vision Sensing

While penetration occurs underneath the workpiece, the raw information used to detect it during welding must be measurable to a sensor attached to the torch. Challenges are apparent because it is difficult to find such measurable raw information that fundamentally correlates with the phenomena occurring underneath. Additional challenges arise because the welding process is extremely complex such that analytically correlating any raw information to the underneath phenomena is practically impossible; therefore, handcrafted methods to propose features from raw information are human dependent and labor extensive. In this paper, the profile of the weld pool surface was proposed as the raw information. An innovative method was proposed to acquire it by projecting a single laser stripe on the weld pool surface transversely and intercepting its reflection from the mirror-like weld pool surface. To minimize human intervention, which can affect success, a deep-learning-based method was proposed to automatically recognize features from the single-stripe active vision images by fitting a convolutional neural network (CNN). To train the CNN, spot gas tungsten arc welding experiments were designed and conducted to collect the active vision images in pairs with their actual penetration states measured by a camera that views the backside surface of the workpiece. The CNN architecture was optimized by trying different hyperparameters, including kernel number, kernel size, and node number. The accuracy of the optimized model is about 98% and the cycle time in the personal computer is ~ 0.1 s, which fully meets the required engineering application.