CALIBRATION OF A CFD METHODOLOGY FOR THE SIMULATION OF ROUGHNESS EFFECTS ON FRICTION AND HEAT TRANSFER IN ADDITIVE MANUFACTURED COMPONENTS

It is well-known from the literature that surface roughness significantly affects friction and heat transfer. This is even more evident for additive manufactured (AM) components, which are taking an increasingly important role in the gas turbine field. However, the exploitation of numerical approaches to improve their design is hindered by the lack of dedicated correlations and CFD models developed for such high roughness conditions. Usually the additive manufactured components are simulated considering the surfaces as smooth or applying an equivalent sand-grain roughness (ks) that results in a velocity shift in the boundary layer. However, determining a priori the most appropriate value of ks is challenging, as dozens of correlations are available, returning scattered and uncertain results. A previous work proved how the CFD prediction of friction and heat transfer returns significant deviations, even exploiting the ks values obtained from experimental tests on the very same test case. That work also allowed identification of a promising CFD methodology based on friction and thermal corrections proposed by Aupoix from ONERA. The aim of this work is to further the assessment and calibration activity of the model, by analyzing additional experimental data of friction factor and Nusselt number from new test cases considering different geometries and flow conditions. The new coupons consisted of straight circular channels and wavy channels. This work represents a further step in the generation of a more validated and general methodology for the high-fidelity CFD analysis of additive-manufactured components.

Wetting Behavior of LBE on Corroded Candidate LFR Structural Materials of 316L, T91 and CLAM

In this work, the wetting behaviors of lead-bismuth eutectic (LBE) on corroded 316L, T91, and CLAM surfaces were studied. The wettability of LBE on virgin and corroded surfaces were tested at 450 °C by using the sessile-drop (SD) method after immersing the samples in LBE with saturated oxygen concentration for 400, 800, and 1200 h at 450°C. Additionally, the morphology, as well as element distribution of the corrosion structure, were characterized by scanning electron microscope (SEM) and energy-dispersive X-ray spectroscopy (EDS). The results showed that the virgin samples of three materials are non-wetting to LBE, and the formation of corrosion structures further reduces the wettability. Besides, the thickness of the corrosion layer formed on the 316L surface grew more slowly than the other two steel, which results in better corrosion resistance of austenitic steel 316L than that of ferritic/martensitic steels T91 and CLAM at 450 °C. Meanwhile, the morphology and distribution of corrosion products are important factors affecting the wettability of the steel surface. The formation of corrosion products with high roughness as well as disorder results in a significant reduction in surface wettability.

Corrosion and Biocompatibility of Pure Zn with a Micro-Arc-Oxidized Layer Coated with Calcium Phosphate

Recent studies have indicated a great demand to optimize the biocompatibility properties of pure Zn as an implant material. For this purpose, CaZn2(PO4)2·2H2O (CaZnP) was prepared using hydrothermal treatment (HT) combined with micro-arc oxidation (MAO) on pure Zn substrate to generate biodegradable implants. The polarization test and electrochemical impedance spectroscopy indicated that the MAO1−HT coating could modulate the corrosion behavior of MAO1 by filling the crevice between the coating and the substrate. Immersion test evaluation revealed that the osteogenic properties of MAO1−HT coating were better than that of pure Zn substrate, as evidenced by the molar ratio of Ca and P, which increased after soaking in simulated body fluid (SBF) for up to 10 days. In addition, L-929 cells cultured in the 100%, 50%, and 25% extracts of MAO1−HT coated samples exhibited excellent cytocompatibility. Meanwhile, cell adhesion was promoted on the surface with high roughness generated during MAO and HT processes. In summary, the calcified coatings improved biocompatibility and adjusted the degradation rates of pure Zn, broadening the application of Zn alloys.

Life and Flaking Failure of 13Cr-2Ni-2Mo and SUS440C Stainless Steel Bearings in Water

The rolling contact fatigue (RCF) tests of 13Cr-2Ni-2Mo and SUS440C stainless steels were carried out in water. Their groove surfaces and the flaking failures were observed. Some hair cracks, wear and high roughness area were found. While the flaking depth of SUS440C was shallower than that of 13Cr-2Ni-2Mo stainless steel, the RCF life of the latter was longer than the former one. The flaking depth did not influence the RCF life.

Effect of Post-Process Curing and Washing Time on Mechanical Properties of mSLA Printouts

The article discusses the influence of the post-process on the mechanical properties of elements produced with the use of the mask stereolithography (mSLA) method. Printed samples were subjected to the following post-process steps: Washing and post-curing, at various times. Then, static tensile and static bending tests were carried out, as well as Shore D hardness measurements for the inner and surface part of the sample, as well as profilographometric analysis of the surface. The post-curing time has been found to strongly affect the tensile and bending strength of printouts, and to improve their surface quality. Washing has an ambiguous effect on the strength of the printouts, but, in the end, it was found that extended washing slightly reduces the strength. Washing significantly affects the quality of the printout surface. A washing time that is too short results in a surface that strongly resembles the printing process, with high roughness. Increasing the washing time to 10 min lowers the roughness by one order of magnitude. Post-curing has also been shown to be beneficial for the cured sample with the application of shielding water. This approach results in an improvement in the flexural strength of the printouts. In general, the obtained research results indicate that, for printouts with cross-sectional dimensions of several mm, the optimal washing time is no more than 10 min and the post-curing time is at least 30 min.

Fabrication of solderable intense pulsed light sintered hybrid copper for flexible conductive electrodes

Additively printed circuits provide advantages in reduced waste, rapid prototyping, and versatile flexible substrate choices relative to conventional circuit printing. Copper (Cu) based inks along with intense pulsed light (IPL) sintering can be used in additive circuit printing. However, IPL sintered Cu typically suffer from poor solderability due to high roughness and porosity. To address this, hybrid Cu ink which consists of Cu precursor/nanoparticle was formulated to seed Cu species and fill voids in the sintered structure. Nickel (Ni) electroplating was utilized to further improve surface solderability. Simulations were performed at various electroplating conditions and Cu cathode surface roughness using the multi-physics finite element method. By utilizing a mask during IPL sintering, conductivity was induced in exposed regions; this was utilized to achieve selective Ni-electroplating. Surface morphology and cross section analysis of the electrodes were observed through scanning electron microscopy and a 3D optical profilometer. Energy dispersive X-ray spectroscopy analysis was conducted to investigate changes in surface compositions. ASTM D3359 adhesion testing was performed to examine the adhesion between the electrode and substrate. Solder-electrode shear tests were investigated with a tensile tester to observe the shear strength between solder and electrodes. By utilizing Cu precursors and novel multifaceted approach of IPL sintering, a robust and solderable Ni electroplated conductive Cu printed electrode was achieved.

Studying floodplain roughness in an Upper Tisza study area

Floods slowing down due to the significant decrease of the gradient have considerable sediment accumulation capacity in the floodplain. The grade of accumulation is further increased if the width of the floodplain is not uniform as water flowing out of the narrow sections diverge and its speed is decreased. Surface roughness in a study area of 492 hectares in the Upper Tisza region was analysed based on CIR (color-infrared) orthophotos from 2007. An NDVI index layer was created first on which object-based image segmentation and threshold-based image classification were performed. The study area is dominated by land cover / land use types (grassland-shrubs, forest) with high roughness values. It was concluded that vegetation activity based analyses on their own are not enough for determining floodplain roughness.

Calibration of a CFD Methodology for the Simulation of Roughness Effects on Friction and Heat Transfer in Additive Manufactured Components

It is well-known from the literature that surface roughness significantly affects friction and heat transfer. This is even more evident for additive manufactured (AM) components, which are taking an increasingly important role in the gas turbine field. However, the exploitation of numerical approaches to improve their design is hindered by the lack of dedicated correlations and CFD models developed for such high roughness conditions. Usually the additive manufactured components are simulated considering the surfaces as smooth or applying an equivalent sand-grain roughness (ks) that results in a velocity shift in the boundary layer. However, determining a priori the most appropriate value of ks is challenging, as dozens of correlations are available, returning scattered and uncertain results. A previous work proved how the CFD prediction of friction and heat transfer returns significant deviations, even exploiting the ks values obtained from experimental tests on the very same test case. That work also allowed identification of a promising CFD methodology based on friction and thermal corrections proposed by Aupoix from ONERA. The aim of this work is to further the assessment and calibration activity of the model, by analyzing additional experimental data of friction factor and Nusselt number from new test cases considering different geometries and flow conditions. The new coupons consisted of straight circular channels and wavy channels. This work represents a further step in the generation of a more validated and general methodology for the high-fidelity CFD analysis of additive-manufactured components.

Structural and Electric Properties of Epitaxial Na0.5Bi0.5TiO3-Based Thin Films

Substantial efforts are dedicated worldwide to use lead-free materials for environmentally friendly processes in electrocaloric cooling. Whereas investigations on bulk materials showed that Na0.5Bi0.5TiO3 (NBT)-based compounds might be suitable for such applications, our aim is to clarify the feasibility of epitaxial NBT-based thin films for more detailed investigations on the correlation between the composition, microstructure, and functional properties. Therefore, NBT-based thin films were grown by pulsed laser deposition on different single crystalline substrates using a thin epitaxial La0.5Sr0.5CoO3 layer as the bottom electrode for subsequent electric measurements. Structural characterization revealed an undisturbed epitaxial growth of NBT on lattice-matching substrates with a columnar microstructure, but high roughness and increasing grain size with larger film thickness. Dielectric measurements indicate a shift of the phase transition to lower temperatures compared to bulk samples as well as a reduced permittivity and increased losses at higher temperatures. Whereas polarization loops taken at −100 °C revealed a distinct ferroelectric behavior, room temperature data showed a significant resistive contribution in these measurements. Leakage current studies confirmed a non-negligible conductivity between the electrodes, thus preventing an indirect characterization of the electrocaloric properties of these films.