This paper investigates the effects of hemispherical mounds on filmwise condensation heat transfer in micro-channels. Also investigated were the impacts that spatial orientation of the three-sided condensation surface (i.e., gravitational effects) on steam condensation, where the cooled surfaces were either the lower surface (i.e., gravity pulls liquid towards the condensing surfaces) or upper surface (i.e., gravity pulls liquid away from the condensing surfaces). Two test coupons were used with 1.9-mm hydraulic diameters and either a plain copper surface or a copper surface modified with 2-mm diameter hemispherical mounds. Heat transfer coefficients, film visualization, and pressure drop measurements were recorded for both coupons in both orientations at mass fluxes of 50 kg/m 2 s and 125 kg/m 2 s. For all test conditions, the mounds were found to increase condensation heat transfer coefficients by at minimum 13% and at maximum 79%. When the test section was inverted (i.e., condensing surface on the top of flowing steam), minimal differences were found in mound performance, while the plain coupon reduces heat transfer coefficients by as much as 14%. Flow visualization suggests that the mounds enhanced heat transfer due to the disruption of the film as well as by reducing the thermal resistance of the film. Pressure drops followed parabolic behavior with quality, being higher in the mound coupon than the plain coupon. No significant pressure drop differences in the inverted orientation were observed.
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Interrogation of Mid-build Internal Temperature Distributions within Parts Being Manufactured via the Powder Bed Fusion Process
This work reports on the measurement of the internal temperature distributions of parts being manufactured via the Powder Bed Fusion (PBF) process. Eight test coupons were machined from a piece of wrought 304 stainless steel (SS). Thermocouples were inserted into the test coupon interiors to sample internal thermal history. The coupons were then placed into the open architecture laser PBF machine housed at EWI and covered to their uppermost surfaces with 316 SS powder.Three tests were executed: First, the laser rastered over the coupons without inducing melting.Second, the laser rastered over the coupons while melting the exposed faces. Lastly, five layers of316 SS were built atop the coupons. The main result is a comprehensive data set of a multitude of measured physical inputs and outputs under typical build conditions: embedded thermocouple temperatures, laser centroid, laser power, and infrared imagery of the exposed coupon faces.
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- Award ID(s):
- 1738723
- PAR ID:
- 10162670
- Date Published:
- Journal Name:
- Proceedings of the 2019 Annual International Solid Freeform Fabrication Symposium
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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This study investigated the influence of diverse laser processing parameters on the thermophysical properties of Ti-6Al-4V and AlSi10Mg alloys manufactured via laser powder bed fusion. During fabrication, the laser power (50 W, 75 W, 100 W) and laser scanning speed (0.2 m/s, 0.4 m/s, 0.6 m/s) were adjusted while keeping other processing parameters constant. Besides laser processing parameters, this study also explored the impact of test temperatures on the thermophysical properties of the alloys. It was found that the thermophysical properties of L-PBF Ti-6Al-4V alloy samples were sensitive to laser processing parameters, while L-PBF AlSi10Mg alloy showed less sensitivity. In general, for the L-PBF Ti-6Al-4V alloy, as the laser power increased and laser scan speed decreased, both thermal diffusivity and conductivity increased. Both L-PBF Ti-6Al-4V and L-PBF AlSi10Mg alloys demonstrated similar dependence on test temperatures, with thermal diffusivity and conductivity increasing as the test temperature rose. The CALPHAD software Thermo-Calc (2023b), applied in Scheil Solidification Mode, was utilized to calculate the quantity of solution atoms, thus enhancing our understanding of observed thermal conductivity variations. A detailed analysis revealed how variations in laser processing parameters and test temperatures significantly influence the alloy’s resulting density, specific heat, thermal diffusivity, and thermal conductivity. This research not only highlights the importance of processing parameters but also enriches comprehension of the mechanisms influencing these effects in the domain of laser powder bed fusion.
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Powder Bed Fusion (PBF) is a type of Additive Manufacturing (AM) technology that builds parts in a layer-by-layer fashion out of a bed of metal powder via the selective melting action of a laser or electron beam heat source. The technology has become widespread, however the demand is growing for closed loop process monitoring and control in PBF systems to replace the open loop architectures that exist today. This paper demonstrates the simulated efficacy of applying closed-loop state estimation to the problem of monitoring temperature fields within parts during the PBF build process. A simplified LTI model of PBF thermal physics with the properties of stability, controllability and observability is presented. An Ensemble Kalman Filter is applied to the model. The accuracy of this filters’ predictions are assessed in simulation studies of the temperature evolution of various test parts when subjected to simulated laser heat input. The significant result of this study is that the filter supplied predictions that were about 2.5x more accurate than the open loop model in these simulation studies.more » « less
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