SCARLET-1.0: SpheriCal Approximation for viRtuaL aggrEgaTes

Aggregation of particles occurs in a large variety of settings and is therefore the focus of many disciplines, e.g., Earth and environmental sciences, astronomy, meteorology, pharmacy, and the food industry. In particular, in volcanology, ash aggregation deeply influences the sedimentation of volcanic particles in the atmosphere during and after a volcanic eruption, affecting the accuracy of model predictions and the evaluation of hazard and risk assessments. It is thus very important to provide an exhaustive description of the outcome of an aggregation process, starting from its basic geometrical features such as the position in space of its components and the overall porosity of the final object. Here we present SCARLET-1.0, a MATLAB package specifically created to provide a 3D virtual reconstruction for volcanic ash aggregates generated in central collision processes. In centrally oriented collisions, aggregates build up their own structure around the first particle (the core), acting as a seed. This is appropriate for aggregates generated in turbulent flows in which particles show different degrees of coupling with respect to the turbulent eddies. SCARLET-1.0 belongs to the class of sphere-composite algorithms, a family of algorithms that approximate 3D complex shapes in terms of a set of sphere-composite nonoverlapping spheres. The conversion of a 3D surface to its equivalent sphere-composite structure then allows for an analytical detection of the intersections between different objects that aggregate together. Thus, provided a list of colliding sizes and shapes, SCARLET-1.0 places each element in the vector around the core, minimizing the distances between their centers of mass. The user can play with different parameters that control the minimization process. Among them the most important ones are the cone of investigation (Ω), the number of rays per cone (Nr), and the number of orientations of the object (No). All the 3D shapes are described using the Standard Triangulation Language (STL) format, which is the current standard for 3D printing. This is one of the key features of SCARLET-1.0, which results in an unlimited range of applications of the package. The main outcome of the code is the virtual representation of the object, its size, porosity, density, and the associated STL file. In addition, the object can be potentially 3D printed. As an example, SCARLET-1.0 has been applied here to the investigation of ellipsoid–ellipsoid collisions and to a more specific analysis of volcanic ash aggregation. In the first application we show that the final porosity of two colliding ellipsoids is less than 20 % if flatness and elongation are greater than or equal to 0.5. Higher values of porosities (up to 40 %–50 %) can instead be found for ellipsoids with needle-like or extremely flat shapes. In the second application, we reconstruct the evolution in time of the porosity of two different aggregates characterized by different inner structures. We find that aggregates whose population of particles is characterized by a narrow distribution of sizes tend to rapidly reach a plateau in the porosity. In addition, to reproduce the observed densities, almost no compaction is necessary in SCARLET-1.0, which is a result that suggests how ash aggregates are not well described in terms of the maximum packing condition.

From monodisperse to polydisperse: the influence of grain size distribution on the mechanical behavior of porous synthetic rocks

<p><span>Sedimentary crustal porous rocks span a wide range of grain size distributions – from monodisperse to highly polydisperse. The distribution of grain size depends on the location and conditions of rock formation, the chemico-physical processes at play, and is influenced by subsequent geological processes. Well-sorted granular rocks, with a grain size distribution close to monodisperse, and granular rocks with a more polydisperse grain size distribution, have repeatedly been subjected to laboratory experiments. And yet the natural variability from sample to sample and structural heterogeneity within single natural samples all conspire to prevent us from constraining the effect of grain size polydispersivity. While a few studies have focused on the influence of grain size, the control of grain size distribution on the mechanical behavior of rocks has scarcely been studied, especially in the laboratory. In this study, we address this knowledge-gap using synthetic samples prepared by sintering glass beads with controlled polydisperse grain size distributions. When heated above the glass transition temperature, the beads act as viscous droplets and sinter together. Throughout viscous sintering, a bead pack evolves from an initial granular discontinuous state into a solid connected porous state, at which the microstructural geometries and final porosity are known. Variably polydisperse individual samples were prepared by mixing glass beads with diameters of 0.2, 0.5, and 1.15 mm in various proportions, which were sintered together to a final porosity of 0.25 or 0.35. Hydrostatic and triaxial compression experiments were performed for each combination of polydispersivity. The samples were water-saturated, deformed at room temperature, and deformed under drained conditions (with a fixed pore pressure of 10 MPa). Triaxial experiments were conducted at a constant strain rate at effective pressure corresponding to the ductile (compactive) regime. Our mechanical data provide evidence that polydispersivity exerts a significant control on the compactive behavior of porous rocks. Insights into the microstructure were gained using scanning electron microscopy on thin sections prepared from samples before and after deformation. These data allow for the observation of the different deformation features, and by extension the deformation micro-mechanisms, promoted by the different type and degree of polydispersivity. Overall, our data show that, at a fixed porosity, increasing polydispersivity decreases the stress required for compactant failure.</span></p>

Porous Zirconia/Magnesia Ceramics Support Osteogenic Potential In Vitro

Porous zirconia (ZrO2), magnesia (MgO) and zirconia/magnesia (ZrO2/MgO) ceramics were synthesised by sintering and designated as ZrO2(100), ZrO2(75)MgO(25), ZrO2(50)MgO(50), ZrO2(25)MgO(75), MgO(100) based on their composition. The ceramic samples were characterised by means of scanning electron microscopy, X-ray diffraction, energy-dispersive X-ray spectroscopy and atomic absorption spectrometry to explore the incorporation of Mg atoms into the zirconia lattice. The resulting porosity of the samples was calculated based on the composition and density. The final porosity of the cylinder-shaped ceramic samples ranged between 30 and 37%. The mechanical analysis exhibited that the Young modulus increased and the microstress decreased with increasing magnesia amount, with values ranging from 175 GPa for zirconia to 301 GPa for magnesia. The adhesion, viability, proliferation and osteogenic activity of MC3T3-E1 pre-osteoblastic cells cultured on the zirconia/magnesia ceramics was found to increase, with the magnesia-containing ceramics exhibiting higher values of calcium mineralisation. The results from the mechanical analysis, the ALP activity, the calcium and collagen production demonstrate that the zirconia/magnesia ceramics possess robust osteoinductive capacity, therefore holding great potential for bone tissue engineering.

SCARLET-1.0: SpheriCal Approximation for viRtuaL aggrEgaTes

Aggregation of particles occurs in a large variety of settings, and, therefore, it is the focus of many disciplines, e.g. Earth and environmental sciences, astronomy, meteorology, pharmacy, food industry. It is thus very important to provide a full description of the outcome of an aggregation process, starting from its basic features such as the position in space of its components and the overall porosity of the final object. We present SCARLET-1.0, a Matlab package specifically created to provide a 3D virtual reconstruction of aggregates in central oriented collisions that can be later 3D printed. With aggregates in central oriented collisions we refer to aggregates that build up their own structure around the first particle (the core) acting as a seed. SCARLET-1.0 belongs to the class of sphere-composite algorithms, a family of algorithms that approximate 3D complex shapes in terms of not-overlapping spheres. The conversion of a 3D surface in its equivalent spherical approximation allows an analytical computation of their intersections. Thus, provided a vector of sizes and shapes, SCARLET-1.0 places each element in the vector around the core minimizing the distances between their centers of mass. The user can play with three main parameters that are in charge of controlling the minimization process, namely the solid angle of the cone of investigation (Ω), the number of rays per cone (Nr), and the number of orientations of the object (No). All the 3D shapes are described using the STL format, the nowadays standard for 3D printing. This is one of the key features of SCARLET-1.0, which results in an unlimited range of application of the package. The main outcome of the code is the virtual representation of the object, its size, porosity, density and the associated STL file. As an example, here SCARLET-1.0 has been applied to the investigation of ellipsoid-ellipsoid collisions and to a more specific analysis of volcanic ash aggregation. In the first application we show that the final porosity of two colliding ellipsoids is less than 20 % if flatness and elongation are greater than or equal to 0.5. Higher values of porosities (up to 40–50 %) can be, instead, found for ellipsoids with needle-like or extremely flat shapes. In the second application, we reconstruct the evolution in time of the porosity of two different aggregates characterized by different inner structures. We find that aggregates whose population of particles is characterized by a narrow distribution of sizes tend to rapidly reach a plateau in the porosity. In addition, to reproduce the observed densities, almost no minimization is necessary in SCARLET-1.0; a result that suggests how these objects are quite far from the maximum packing condition often investigated in literature.

Porosity Reducing Processing Stages of Additive Manufactured Molding (AMM) for Closed-Mold Composite Fabrication

This article aims to merge two evolving technologies, namely additive manufacturing and composite manufacturing, to achieve the production of high-quality and low-cost composite structures utilizing additive manufacturing molding technology. This work studied additive manufacturing processing parameters at various processing stages on final printed part performance, specifically how altering featured wall thickness and layer height combine to affect final porosity. Results showed that reducing the layer height yielded a 90% improvement in pristine porosity reduction. Optimal processing parameters were combined and utilized to design and print a closed additive manufacturing molding tool to demonstrate flexible composite manufacturing by fabricating a composite laminate. Non-destructive and destructive methods were used to analyze the composite structures. Compared to the well-established composite manufacturing processes of hand lay-up and vacuum-assisted resin transfer molding methods, additive manufacturing molding composites were shown to have comparable material strength properties.

Design of Thermoplastic 3D-Printed Scaffolds for Bone Tissue Engineering: Influence of Parameters of “Hidden” Importance in the Physical Properties of Scaffolds

Additive manufacturing (AM) techniques are becoming the approaches of choice for the construction of scaffolds in tissue engineering. However, the development of 3D printing in this field brings unique challenges, which must be accounted for in the design of experiments. The common printing process parameters must be considered as important factors in the design and quality of final 3D-printed products. In this work, we study the influence of some parameters in the design and fabrication of PCL scaffolds, such as the number and orientation of layers, but also others of “hidden” importance, such as the cooling down rate while printing, or the position of the starting point in each layer. These factors can have an important impact oin the final porosity and mechanical performance of the scaffolds. A pure polycaprolactone filament was used. Three different configurations were selected for the design of the internal structure of the scaffolds: a solid one with alternate layers (solid) (0°, 90°), a porous one with 30% infill and alternate layers (ALT) (0°, 90°) and a non-alternated configuration consisting in printing three piled layers before changing the orientation (n-ALT) (0°, 0°, 0°, 90°, 90°, 90°). The nozzle temperature was set to 172 °C for printing and the build plate to 40 °C. Strand diameters of 361 ± 26 µm for room temperature cooling down and of 290 ± 30 µm for forced cooling down, were obtained. A compression elastic modulus of 2.12 ± 0.31 MPa for n-ALT and 8.58 ± 0.14 MPa for ALT scaffolds were obtained. The cooling down rate has been observed as an important parameter for the final characteristics of the scaffold.

Experimental study of void evolution in partially impregnated prepregs

Controlling voids to minimize the final porosity level is an important concern when processing advanced composite structures. In this study, the porosity evolution during processing of partially impregnated prepregs is investigated using interrupted cure cycles and optical microscopy. Laminates made of MTM 45-1/5HS carbon/epoxy prepreg subjected to different cure cycles, bagging conditions, and humidity levels were studied. Fiber tow geometry and gas permeability were measured to determine the amount of compaction and the interconnectivity of unsaturated zones in the laminates. Three types of voids were identified: inter-laminar, fiber tow and resin voids, all with different origins and evolution patterns. It is shown that gas transport (both in-plane and through-thickness), fiber bed compaction, and resin infiltration govern void evolution during processing. The results provide insights for development of representative transport models and to optimize processing cycles.

The Influence of the Tablet Height and Plunger Pressing Velocity on the Final Porosity of Die Casting

With a pressure die casting process, one of the important factors affecting the quality of castings represented by porosity is plunger pressing velocity determines the regime die cavity filling and correct determination of dose mass of a molten metal required for one casting cycle. The mass is given by a total of the net mass of a casting, overflows, a gate system and a metal rest inside a filling chamber (the tablet height). As a rule, the tablet height represents the largest mass ratio regarding the waste metal. A correct determination of the tablet height is important from both economical and qualitative aspect of a pressure die casting process.

Research and Development of the Solidification of Slab Ingots from Special Tool Steels

The paper describes the research and development of casting and solidification of slab ingots from special tool steels by means of numerical modelling using the finite element method. The pre-processing, processing and post-processing phases of numerical modelling are outlined. Also, problems with determining the thermophysical properties of materials and heat transfer between the individual parts of the casting system are discussed. Based on the type of grade of tool steel, the risk of final porosity is predicted. The results allowed to improve the production technology of slab ingots, and also to verify the ratio, the chamfer and the external/ internal shape of the wall of the new designed slab ingots.