Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation

Among the many additive manufacturing (AM) processes for metallic materials, selective laser melting (SLM) is arguably the most versatile in terms of its potential to realize complex geometries along with tailored microstructure. However, the complexity of the SLM process, and the need for predictive relation of powder and process parameters to the part properties, demands further development of computational and experimental methods. This review addresses the fundamental physical phenomena of SLM, with a special emphasis on the associated thermal behavior. Simulation and experimental methods are discussed according to three primary categories. First, macroscopic approaches aim to answer questions at the component level and consider for example the determination of residual stresses or dimensional distortion effects prevalent in SLM. Second, mesoscopic approaches focus on the detection of defects such as excessive surface roughness, residual porosity or inclusions that occur at the mesoscopic length scale of individual powder particles. Third, microscopic approaches investigate the metallurgical microstructure evolution resulting from the high temperature gradients and extreme heating and cooling rates induced by the SLM process. Consideration of physical phenomena on all of these three length scales is mandatory to establish the understanding needed to realize high part quality in many applications, and to fully exploit the potential of SLM and related metal AM processes

Numerical product design: Springback prediction, compensation and optimization

Numerical simulations are being deployed widely for product design. However, the accuracy of the numerical tools is not yet always sufficiently accurate and reliable. This article focuses on the current state and recent developments in different stages of product design: springback prediction, springback compensation and optimization by finite element (FE) analysis. To improve the springback prediction by FE analysis, guidelines regarding the mesh discretization are provided and a new through-thickness integration scheme for shell elements is launched. In the next stage of virtual product design the product is compensated for springback. Currently, deformations due to springback are manually compensated in the industry. Here, a procedure to automatically compensate the tool geometry, including the CAD description, is presented and it is successfully applied to an industrial automotive part. The last stage in virtual product design comprises optimization. This article presents an optimization scheme which is capable of designing optimal and robust metal forming processes efficiently

Evaluating the Differences of Gridding Techniques for Digital Elevation Models Generation and Their Influence on the Modeling of Stony Debris Flows Routing: A Case Study From Rovina di Cancia Basin (North-Eastern Italian Alps)

Debris \ufb02ows are among the most hazardous phenomena in mountain areas. To cope with debris \ufb02ow hazard, it is common to delineate the risk-prone areas through routing models. The most important input to debris \ufb02ow routing models are the topographic data, usually in the form of Digital Elevation Models (DEMs). The quality of DEMs depends on the accuracy, density, and spatial distribution of the sampled points; on the characteristics of the surface; and on the applied gridding methodology. Therefore, the choice of the interpolation method affects the realistic representation of the channel and fan morphology, and thus potentially the debris \ufb02ow routing modeling outcomes. In this paper, we initially investigate the performance of common interpolation methods (i.e., linear triangulation, natural neighbor, nearest neighbor, Inverse Distance to a Power, ANUDEM, Radial Basis Functions, and ordinary kriging) in building DEMs with the complex topography of a debris \ufb02ow channel located in the Venetian Dolomites (North-eastern Italian Alps), by using small footprint full- waveform Light Detection And Ranging (LiDAR) data. The investigation is carried out through a combination of statistical analysis of vertical accuracy, algorithm robustness, and spatial clustering of vertical errors, and multi-criteria shape reliability assessment. After that, we examine the in\ufb02uence of the tested interpolation algorithms on the performance of a Geographic Information System (GIS)-based cell model for simulating stony debris \ufb02ows routing. In detail, we investigate both the correlation between the DEMs heights uncertainty resulting from the gridding procedure and that on the corresponding simulated erosion/deposition depths, both the effect of interpolation algorithms on simulated areas, erosion and deposition volumes, solid-liquid discharges, and channel morphology after the event. The comparison among the tested interpolation methods highlights that the ANUDEM and ordinary kriging algorithms are not suitable for building DEMs with complex topography. Conversely, the linear triangulation, the natural neighbor algorithm, and the thin-plate spline plus tension and completely regularized spline functions ensure the best trade-off among accuracy and shape reliability. Anyway, the evaluation of the effects of gridding techniques on debris \ufb02ow routing modeling reveals that the choice of the interpolation algorithm does not signi\ufb01cantly affect the model outcomes

Image and Volume Segmentation by Water Flow

A general framework for image segmentation is presented in this paper, based on the paradigm of water flow. The major water flow attributes like water pressure, surface tension and capillary force are defined in the context of force field generation and make the model adaptable to topological and geometrical changes. A flow-stopping image functional combining edge- and region-based forces is introduced to produce capability for both range and accuracy. The method is assessed qualitatively and quantitatively on synthetic and natural images. It is shown that the new approach can segment objects with complex shapes or weak-contrasted boundaries, and has good immunity to noise. The operator is also extended to 3-D, and is successfully applied to medical volume segmentation

Effect of contact angle hysteresis on thermocapillary droplet actuation

Open microfluidic devices based on actuation techniques such as electrowetting, dielectrophoresis, or thermocapillary stresses require controlled motion of small liquid droplets on the surface of glass or silicon substrates. In this article we explore the physical mechanisms affecting thermocapillary migration of droplets generated by surface temperature gradients on the supporting substrate. Using a combination of experiment and modeling, we investigate the behavior of the threshold force required for droplet mobilization and the speed after depinning as a function of the droplet size, the applied thermal gradient and the liquid material parameters. The experimental results are well described by a hydrodynamic model based on earlier work by Ford and Nadim. The model describes the steady motion of a two-dimensional droplet driven by thermocapillary stresses including contact angle hysteresis. The results of this study highlight the critical role of chemical or mechanical hysteresis and the need to reduce this retentive force for minimizing power requirements in microfluidic devices

Second All-Union Seminar on Hydromechanics and Heat and Mass Exchange in Weightlessness, summaries of reports

Abstracts of reports are given which were presented at the Second All Union Seminar on Hydromechanics and Heat-Mass Transfer in Weightlessness. Topics include: (1) features of crystallization of semiconductor materials under conditions of microacceleration; (2) experimental results of crystallization of solid solutions of CDTE-HGTE under conditions of weightlessness; (3) impurities in crystals cultivated under conditions of weightlessness; and (4) a numerical investigation of the distribution of impurities during guided crystallization of a melt