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

Computational study of heat transfer in solar collectors with different radiative flux models

2D steady incompressible laminar Newtonian viscous convection-radiative heat transfer in a rectangular solar collector geometry is considered. The ANSYS FLUENT finite volume code (version 17.2) is employed to simulate the thermo-fluid characteristics. Extensive details of computational methodology are given to provide engineers with a framework for simulating radiative-convection in enclosures. Mesh-independence tests and validation are conducted. The influence of aspect ratio, Prandtl number (Pr), Rayleigh number (Ra) and radiative flux model on temperature, isotherms, velocity, pressure is evaluated and visualized in colour plots. Additionally, local convective heat flux is computed, and solutions are compared with the MAC solver for various buoyancy effects achieving excellent agreement. The P1 model is shown to better predict the actual influence of solar radiative flux on thermal fluid behaviour compared with the limited Rosseland model. With increasing Ra, the hot zone emanating from the base of the collector is found to penetrate deeper into the collector and rises symmetrically dividing into two vortex regions with very high buoyancy effect. With increasing Pr there is a progressive incursion of the hot zone at the solar collector base higher into the solar collector space and simultaneously a greater asymmetric behaviour of the dual isothermal zones

Depth-averaged and 3D Finite Volume numerical models for viscous fluids, with application to the simulation of lava flows

This Ph.D. project was initially born from the motivation to contribute to the depth-averaged and 3D modeling of lava flows. Still, we can frame the work done in a broader and more generalist vision. We developed two models that may be used for generic viscous fluids, and we applied efficient numerical schemes for both cases, as explained in the following. The new solvers simulate free-surface viscous fluids whose temperature changes are due to radiative, convective, and conductive heat exchanges. A temperature-dependent viscoplastic model is used for the final application to lava flows. Both the models behind the solvers were derived from mass, momentum, and energy conservation laws. Still, one was obtained by following the depth-averaged model approach and the other by the 3D model approach. The numerical schemes adopted in both our models belong to the family of finite volume methods, based on the integral form of the conservation laws. This choice of methods family is fundamental because it allows the creation and propagation of discontinuities in the solutions and enforces the conservation properties of the equations. We propose a depth-averaged model for a viscous fluid in an incompressible and laminar regime with an additional transport equation for a scalar quantity varying horizontally and a variable density that depends on such transported quantity. Viscosity and non-constant vertical profiles for the velocity and the transported quantity are assumed, overtaking the classic shallow-water formulation. The classic formulation bases on several assumptions, such as the fact that the vertical pressure distribution is hydrostatic, that the vertical component of the velocity can be neglected, and that the horizontal velocity field can be considered constant with depth because the classic formulation accounts for non-viscous fluids. When the vertical shear is essential, the last assumption is too restrictive, so it must relax, producing a modified momentum equation in which a coefficient, known as the Boussinesq factor, appears in the advective term. The spatial discretization method we employed is a modified version of the central-upwind scheme introduced by Kurganov and Petrova in 2007 for the classical shallow water equations. This method is based on a semi-discretization of the computational domain, is stable, and, being a high-order method, has a low numerical diffusion. For the temporal discretization, we used an implicit-explicit Runge-Kutta technique discussed by Russo in 2005 that permits an implicit treatment of the stiff terms. The whole scheme is proved to preserve the positivity of flow thickness and the stationary steady-states. Several numerical experiments validate the proposed method, show the incidence on the numerical solutions of shape coefficients introduced in the model and present the effects of the viscosity-related parameters on the final emplacement of a lava flow. Our 3D model describes the dynamics of two incompressible, viscous, and immiscible fluids, possibly belonging to different phases. Being interested in the final application of lava flows, we also have an equation for energy that models the thermal exchanges between the fluid and the environment. We implemented this model in OpenFOAM, which employs a segregated strategy and the Finite Volume Methods to solve the equations. The Volume of Fluid (VoF) technique introduced by Hirt and Nichols in 1981 is used to deal with the multiphase dynamics (based on the Interphase Capturing strategy), and hence a new transport equation for the volume fraction of one phase is added. The challenging effort of maintaining an accurate description of the interphase between fluids is solved by using the Multidimensional Universal Limiter for Explicit Solution (MULES) method (described by Marquez Damian in 2013) that implements the Flux-Corrected Transport (FCT) technique introduced by Boris and Book in 1973, proposing a mix of high and low order schemes. The choice of the framework to use for any new numerical code is crucial. Our contribution consists of creating a new solver called interThermalRadConvFoam in the OpenFOAM framework by modifying the already existing solver interFoam (described by Deshpande et al. in 2012). Finally, we compared the results of our simulations with some benchmarks to evaluate the performances of our model

TPCI: The PLUTO-CLOUDY Interface

We present an interface between the (magneto-) hydrodynamics code PLUTO and the plasma simulation and spectral synthesis code CLOUDY. By combining these codes, we constructed a new photoionization hydrodynamics solver: The PLUTO-CLOUDY Interface (TPCI), which is well suited to simulate photoevaporative flows under strong irradiation. The code includes the electromagnetic spectrum from X-rays to the radio range and solves the photoionization and chemical network of the 30 lightest elements. TPCI follows an iterative numerical scheme: First, the equilibrium state of the medium is solved for a given radiation field by CLOUDY, resulting in a net radiative heating or cooling. In the second step, the latter influences the (magneto-) hydrodynamic evolution calculated by PLUTO. Here, we validated the one-dimensional version of the code on the basis of four test problems: Photoevaporation of a cool hydrogen cloud, cooling of coronal plasma, formation of a Stroemgren sphere, and the evaporating atmosphere of a hot Jupiter. This combination of an equilibrium photoionization solver with a general MHD code provides an advanced simulation tool applicable to a variety of astrophysical problems.Comment: 13 pages, 10 figures, accepted for publication in A&

A fast GPU Monte Carlo Radiative Heat Transfer Implementation for Coupling with Direct Numerical Simulation

We implemented a fast Reciprocal Monte Carlo algorithm, to accurately solve radiative heat transfer in turbulent flows of non-grey participating media that can be coupled to fully resolved turbulent flows, namely to Direct Numerical Simulation (DNS). The spectrally varying absorption coefficient is treated in a narrow-band fashion with a correlated-k distribution. The implementation is verified with analytical solutions and validated with results from literature and line-by-line Monte Carlo computations. The method is implemented on GPU with a thorough attention to memory transfer and computational efficiency. The bottlenecks that dominate the computational expenses are addressed and several techniques are proposed to optimize the GPU execution. By implementing the proposed algorithmic accelerations, a speed-up of up to 3 orders of magnitude can be achieved, while maintaining the same accuracy

Heat Exchange Numerical Modeling of a Submarine Pipeline for Crude Oil Transport

Abstract The present paper deals with a real issue of the Exxon-Mobil refinery in Augusta (Sicily). The crude oil, which is transported by oil tankers, is transferred through a submarine pipeline where it remains for a long time. In order to predict the transient temperature of the pipe, two numerical approaches were developed. The simplest one was a conductive model, based on the Finite Element Method, implemented by using the ANSYS Thermal FEM software for a first approximation solution. After having carried out an accurate grid resolution study and having evaluated the thermal error, a prediction of thermal profiles and heat fluxes was obtained. Thanks to the axisymmetrics of the physical problem, only a limited portion of the 3D pipe was modelled. The second approach was instead based on the use of a more accurate CFD Finite Volume Model, developed in ANSYS Fluent. In this case, in order to have reasonable calculation time and thanks to the aforementioned axisymetrics, the problem was carried out in 2D. Moreover, both grid and time step sensitivity was evaluated. Accurate buoyancy and turbulence models as well as viscosity and density temperature dependence models were used in order to obtain the most accurate physical modelling. The CFD model was developed basing on codes validated in the scientific literature. The comparison between FEM conductive and CFD results demonstrated the superior accuracy of the CFD, thanks to an accurate modelling of the internal convective motions

Radiative Conductivity Estimation Using Direct Approach For Fibrous Materials

During planetary entry, space vehicles encounter high loads of thermal energy which requires a thermal protection system. Ablative thermal protection systems are usually made out of fibrous materials that exhibit internal radiation. In order to model the internal radiation response of a thermal protection system one should obtain proper radiative properties as well as thermal properties. The objective of this work is to provide a method that solves for the solid/gas thermal conductivity. Which can be used in coupled detailed radiative analysis. Keywords: radiative conductivity, fibrous materials, radiative transfer, thermal protection system, P1 approximation, Finite Volume method

Discrete-Ordinates Modelling of the Radiative Heat Transfer in a Pilot-Scale Rotary Kiln

This paper presents work focused on the development, evaluation and use of a 3D model for investigation of the radiative heat transfer in rotary kilns. The model applies a discrete-ordinates method to solve the radiative transfer equation considering emission, absorption and scattering of radiation by gas species and particles for cylindrical and semi-cylindrical enclosures. Modelling input data on temperature, particle distribution and gas composition in the radial, axial and angular directions are experimentally gathered in a down-scaled version of a rotary kiln. The model is tested in its capability to predict the radiative intensity and heat flux to the inner wall of the furnace and good agreement was found when compared to measurements. Including the conductive heat transfer through the furnace wall, the model also satisfactorily predicts the intermediate wall temperature. The work also includes a first study on the effect of the incident radiative heat flux to the different surfaces while adding a cold bed material. With further development of the model, it can be used to study the heat transfer in full-scale rotary kilns