Hardness, grainsize and porosity formation prediction on the Laser Metal Deposition of AISI 304 stainless steel

The presented numerical model solves the heat and mass transfer equations in the Laser Metal Deposition process and based on the evolution of the thermal field predicts the grainsize, the resulting hardness and evaluates the pores formation probability in an AISI 304 stainless steel. For this purpose, in a first step, the model calculates the shape of the deposited material and the variations of the temperature field. In a second step, and based on the evolution of the thermal field, the model calculates the resulting hardness of the deposited material, the grainsize and the porosity formation probability after the deposition process. Numerical results are experimentally validated, and good agreement is obtained. Consequently, besides predicting the geometry of the resulting part and the evolution of the thermal field, the developed model enables to evaluate the quality of the deposited material. Therefore, the optimum process conditions and strategy when depositing AISI 304 stainless steel can be determined without initial trial-and-error tests.“LaCaixa” foundation . In addition, this work has been founded by the H2020- FoF13-2016 PARADDISE project (contract No.: 723440). This work has been also carried out in the framework of the DPI2016-79889-R – INTEGRADDI project, funded by the Spanish Ministry of Industry and Competitiveness

Energy efficiency in discrete-manufacturing systems: insights, trends, and control strategies

Since the depletion of fossil energy sources, rising energy prices, and governmental regulation restrictions, the current manufacturing industry is shifting towards more efficient and sustainable systems. This transformation has promoted the identification of energy saving opportunities and the development of new technologies and strategies oriented to improve the energy efficiency of such systems. This paper outlines and discusses most of the research reported during the last decade regarding energy efficiency in manufacturing systems, the current technologies and strategies to improve that efficiency, identifying and remarking those related to the design of management/control strategies. Based on this fact, this paper aims to provide a review of strategies for reducing energy consumption and optimizing the use of resources within a plant into the context of discrete manufacturing. The review performed concerning the current context of manufacturing systems, control systems implemented, and their transformation towards Industry 4.0 might be useful in both the academic and industrial dimension to identify trends and critical points and suggest further research lines.Peer ReviewedPreprin

Numerical modeling of the electron beam welding and its experimental validation

Electron Beam Welding (EBW) is a highly efficient and precise welding method increasingly used within the manufacturing chain and of growing importance in different industrial environments such as the aeronautical and aerospace sectors. This is because, compared to other welding processes, EBW induces lower distortions and residual stresses due to the lower and more focused heat input along the welding line. This work describes the formulation adopted for the numerical simulation of the EBW process as well as the experimental work carried out to calibrate and validate it. The numerical simulation of EBW involves the interaction of thermal, mechanical and metallurgical phenomena. For this reason, in this work the numerical framework couples the heat transfer process to the stress analysis to maximize accuracy. An in-house multi-physics FE software is used to deal with the numerical simulation. The definition of an ad hoc moving heat source is proposed to simulate the EB power surface distribution and the corresponding absorption within the work-piece thickness. Both heat conduction and heat radiation models are considered to dissipate the heat through the boundaries of the component. The material behavior is characterized by an apropos thermo-elasto-viscoplastic constitutive model. Titanium-alloy Ti6A14V is the target material of this work. From the experimental side, the EB welding machine, the vacuum chamber characteristics and the corresponding operative setting are detailed. Finally, the available facilities to record the temperature evolution at different thermo-couple locations as well as to measure both distortions and residual stresses are described. Numerical results are compared with the experimental evidence.Peer ReviewedPostprint (author's final draft

Technical design and commissioning of the KATRIN large-volume air coil system

The KATRIN experiment is a next-generation direct neutrino mass experiment with a sensitivity of 0.2 eV (90% C.L.) to the effective mass of the electron neutrino. It measures the tritium $\beta$-decay spectrum close to its endpoint with a spectrometer based on the MAC-E filter technique. The $\beta$-decay electrons are guided by a magnetic field that operates in the mT range in the central spectrometer volume; it is fine-tuned by a large-volume air coil system surrounding the spectrometer vessel. The purpose of the system is to provide optimal transmission properties for signal electrons and to achieve efficient magnetic shielding against background. In this paper we describe the technical design of the air coil system, including its mechanical and electrical properties. We outline the importance of its versatile operation modes in background investigation and suppression techniques. We compare magnetic field measurements in the inner spectrometer volume during system commissioning with corresponding simulations, which allows to verify the system's functionality in fine-tuning the magnetic field configuration. This is of major importance for a successful neutrino mass measurement at KATRIN.Comment: 32 pages, 16 figure

Mathematics at the eve of a historic transition in biology

A century ago physicists and mathematicians worked in tandem and established quantum mechanism. Indeed, algebras, partial differential equations, group theory, and functional analysis underpin the foundation of quantum mechanism. Currently, biology is undergoing a historic transition from qualitative, phenomenological and descriptive to quantitative, analytical and predictive. Mathematics, again, becomes a driving force behind this new transition in biology.Comment: 5 pages, 2 figure

Generation of Warm Dense Plasma on Solar Panel Infrastructure in Exo-Atmospheric Conditions

The use of a weaponized thermo-nuclear device in exo-atmospheric conditions would be of great impact on the material integrity of orbiting satellite infrastructure. Particular damage would occur to the multi-layered, solar cell components of such satellites. The rapid absorption of X-ray radiation originating from a nuclear blast into these layers occurs over a picosecond time scale and leads to the generation of Warm Dense Plasma (WDP). While incredibly difficult and costly to replicate in a laboratory setting, a collection of computational techniques and software libraries may be utilized to simulate the intricate atomic and subatomic physics characteristics of such an event. Use of the Monte Carlo sampling method within the Geant4 software library allows for the energy deposition and power density profiles by X-rays into this system to be determined. By understanding and modeling the different factors which can affect the absorption of thermonuclear X-ray radiation, specifically, “cold –X-ray radiation,” in the energy range of approximately 1 to 1.5 keV, the molecular dynamics modeling of WDP generation and evolution can be performed using the LAMMPS code library. One aspect modeled and utilized within this software is the Planck blackbody spectrum of X-rays, assumed to be emitted by the detonation. Another such factor explored is the effect of primary and secondary particle backscattering within the active solar cell layer. Ultimately, it was determined that the primary and secondary particle backscattering of photons and electrons occurs at such a relatively low rate that its effect on the properties of the generated WDP is negligible. Once the energy deposition and power density profiles are determined, LAMMPS is utilized in order to understand the spatio-temporal evolution of the WDP as well as the temperature, stress, and mass density distribution within the material, at its surface, and its immediate vacuum surroundings