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Slag defects remain a persisting and prominent problem for steel foundries across the world. Slag defects are surface defects usually caused by oxides transported from the pouring ladle or formed during the initial stages of filling that are transported into the casting cavity during pouring. This study investigates the use of vortex chambers as a component of the gating system and a potential slag trapping mechanism for ferrous metals through computational modeling and experimental validations. Six vortex chamber designs were studied using 3D sand-printing (3DSP) with varying chamber thickness and inlet-outlet height difference. For experimental validation, ASTM A216 WCB steel plates were cast using these vortex chamber designs. The results were compared to a benchmark design consisting of a conventional straight runner section in place of the vortex chamber. Computational results include ingate velocity during filling, entrained air volume fraction, and free surface defect mass. Experimental results include a subsurface pore volume fraction model based on the measured ultrasonic wave speed and attenuation. The experimental results were correlated with the computational results and show strong agreement. The computational results suggest a 31% reduction in melt velocity at the ingate from one of the vortex chamber designs and confirming the reduction in turbulence and reoxidation in the melt stream. However, the experimental results suggest no significant improvement in terms of subsurface porosity for the vortex chamber designs based on previous literature. 

3D sand printing (3DSP) is a comparatively new additive manufacturing (AM) technology which has opened new opportunities for the sand-casting industry. Complex parts with intricate features that were inaccessible through the traditional mold and core making process and would take significant lead time to production can be now easily manufactured using 3DSP technology. Previous studies through numerical modeling have revealed that novel 3D riser geometries offer significant advantages during solidification of the casting by providing higher solidification time, less macro-porosity, and less piping inside the riser. This current study focuses on the experimental validation of the numerical study. Nine different riser geometries were printed as cores using 3DSP which were later installed in a larger sand mold accommodating the rigging (sprue, runners, ingates). Three novel riser shapes (ellipsoid, spherical and fusion) and one traditional cylindrical riser were explored in this study. The spherical risers were studied to understand the effect of the novel riser shape on the neck region. With three repetitions of each design (total of nine designs), a total of 27 castings were manufactured and characterized for statistical analysis. ASTM A216 WCB (wrought carbon steel, grade B) alloy was used to pour all the molds. Results from the ultrasonic tests, flexural test, and X-ray CT inspection show strong agreement with the previous FEA analysis along with 45 % yield improvement, 32 % reduction in riser neck diameter and increased mechanical strength. 

The gravity-induced depth-dependent elastic properties of a granular half-space result in multiple dispersive surface modes and demand the consideration of material heterogeneity in metabarrier designs to suppress surface waves. Numerous locally resonant metabarrier configurations have been proposed in the literature to suppress Rayleigh surface waves in homogeneous media, with little focus on extending the designs to a heterogeneous half-space. In this work, a metabarrier comprising partially embedded rod-like resonators to suppress the fundamental dispersive surface wave modes in heterogeneous granular media known as first order PSV (PSV1; where P is the longitudinal mode and SV is the shear-vertical mode) and second order PSV (PSV2) is proposed. The unit-cell dispersion analysis, together with an extensive frequency-domain finite element analysis, reveals preferential hybridization of the PSV1 and PSV2 modes with the longitudinal and flexural resonances of the resonators, respectively. The presence of the cutoff frequency for the longitudinal-resonance hybridized mode facilitates straightforward suppression of the PSV1 mode, while PSV2 mode suppression is possible by tailoring the hybridized flexural resonance modes. These PSV1 and PSV2 bandgaps are realized experimentally in a granular testbed comprising glass beads by embedding 3D-printed resonator rods. Also explored are novel graded metabarriers capable of suppressing both PSV1 and PSV2 modes over a broad frequency range for potential applications in vibration control and seismic isolation. 

Locally resonant elastodynamic metasurfaces for suppressing surface waves have gained popularity in recent years, especially because of their potential in low-frequency applications such as seismic barriers. Their design strategy typically involves tailoring geometrical features of local resonators to attain a desired frequency bandgap through extensive dispersion analyses. In this paper, a systematic design methodology is presented to conceive these local resonators using topology optimization, where frequency bandgaps develop by matching multiple antiresonances with predefined target frequencies. The design approach modifies an individual resonator's response to unidirectional harmonic excitations in the in-plane and out-of-plane directions, mimicking the elliptical motion of surface waves. Once an arrangement of optimized resonators composes a locally resonant metasurface, frequency bandgaps appear around the designed antiresonance frequencies. Numerical investigations analyze three case studies, showing that longitudinal-like and flexural-like antiresonances lead to nonoverlapping bandgaps unless both antiresonance modes are combined to generate a single and wider bandgap. Experimental data demonstrate good agreement with the numerical results, validating the proposed design methodology as an effective tool to realize locally resonant metasurfaces by matching multiple antiresonances such that bandgaps generated as a result of in-plane and out-of-plane surface wave motion combine into wider bandgaps. 

Abstract In this article, we present a design methodology for resonant structures exhibiting particular dynamic responses by combining an eigenfrequency matching approach and a harmonic analysis-informed eigenmode identification strategy. This systematic design methodology, based on topology optimization, introduces a novel computationally efficient approach for 3D dynamic problems requiring antiresonances at specific target frequencies subject to specific harmonic loads. The optimization’s objective function minimizes the error between target antiresonance frequencies and the actual structure’s antiresonance eigenfrequencies, while the harmonic analysis-informed identification strategy compares harmonic displacement responses against eigenvectors using a modal assurance criterion, therefore ensuring an accurate recognition and selection of appropriate antiresonance eigenmodes used during the optimization process. At the same time, this method effectively prevents well-known problems in topology optimization of eigenfrequencies such as localized eigenmodes in low-density regions, eigenmodes switching order, and repeated eigenfrequencies. Additionally, our proposed localized eigenmode identification approach completely removes the spurious eigenmodes from the optimization problem by analyzing the eigenvectors’ response in low-density regions compared to high-density regions. The topology optimization problem is formulated with a density-based parametrization and solved with a gradient-based sequential linear programming method, including material interpolation models and topological filters. Two case studies demonstrate that the proposed design methodology successfully generates antiresonances at the desired target frequency subject to different harmonic loads, design domain dimensions, mesh discretization, or material properties. 

Abstract Predicting failure in solids has broad applications including earthquake prediction which remains an unattainable goal. However, recent machine learning work shows that laboratory earthquakes can be predicted using micro-failure events and temporal evolution of fault zone elastic properties. Remarkably, these results come from purely data-driven models trained with large datasets. Such data are equivalent to centuries of fault motion rendering application to tectonic faulting unclear. In addition, the underlying physics of such predictions is poorly understood. Here, we address scalability using a novel Physics-Informed Neural Network (PINN). Our model encodes fault physics in the deep learning loss function using time-lapse ultrasonic data. PINN models outperform data-driven models and significantly improve transfer learning for small training datasets and conditions outside those used in training. Our work suggests that PINN offers a promising path for machine learning-based failure prediction and, ultimately for improving our understanding of earthquake physics and prediction. 

An array of surface-mounted prismatic resonators in the path of Rayleigh wave propagation generates two distinct types of surface-wave bandgaps: longitudinal and flexural-resonance bandgaps, resulting from the hybridization of the Rayleigh wave with the longitudinal and flexural resonances of the resonators, respectively. Longitudinal-resonance bandgaps are broad with asymmetric transmission drops, whereas flexural-resonance bandgaps are narrow with nearly symmetric transmission drops. In this paper, we illuminate these observations by investigating the resonances and anti-resonances of the resonator. With an understanding of how the Rayleigh wave interacts with different boundary conditions, we investigate the clamping conditions imposed by prismatic resonators due to the resonator’s resonances and anti-resonances and interpret the resulting transmission spectra. We demonstrate that, in the case of a single resonator, only the resonator’s longitudinal and flexural resonances are responsible for suppressing Rayleigh waves. In contrast, for a resonator array, both the resonances and the anti-resonances of the resonators contribute to the formation of the longitudinal-resonance bandgaps, unlike the flexural-resonance bandgaps where only the flexural resonances play a role. We also provide an explanation for the observed asymmetry in the transmission drop within the longitudinal-resonance bandgaps by assessing the clamping conditions imposed by the resonators. Finally, we evaluate the transmission characteristics of resonator arrays at the anti-resonance frequencies by varying a few key geometric parameters of the unit cell. These findings provide the conceptual understanding required to design optimized resonators based on matching anti-resonance frequencies with the incident Rayleigh wave frequency in order to achieve enhanced Rayleigh wave suppression. 

A locally resonant meta-surface for preferential excitation of a guided mode in a hollow pipe can improve ultrasonic guided wave inspection of pipelines. The proposed meta-surface comprises a periodic arrangement of bonded prismatic rod-like resonators in the circumferential and axial directions of the pipe. We demonstrate the presence of bandgaps for the low-frequency axisymmetric longitudinal modes L(0,1) and L(0,2) and the torsional mode T(0,1). The generated bandgaps can be used to filter the higher harmonics associated with the system nonlinearity to improve nonlinear ultrasonic measurements on pipes. These bandgaps exist even for the non-axisymmetric flexural modes but with their hybridized dispersion curves exhibiting mode-coupling for higher circumferential orders. Moreover, a “partial” bandgap is obtained where preferential transmission of the L(0,2) mode over L(0,1) is possible. We discuss the potential advantages of this partial bandgap to improve pipeline inspections using the L(0,2) mode. Time-domain finite element analyses are used to validate the presence of these bandgaps under radial, circumferential, and axial excitation that mimics the excitation using a ring of piezoelectric transducers. Finally, we discuss the influence of resonator spacing, filling fraction, and the number of resonator rings on the bandgaps for an informed meta-surface design.