Variable Powder Flow Rate Control in Laser Metal Deposition Processes

This paper proposes a novel technique, called Variable Powder Flow Rate Control (VPFRC), for the regulation of powder flow rate in laser metal deposition processes. The idea of VPFRC is to adjust the powder flow rate to maintain a uniform powder deposition per unit length even when disturbances occur (e.g., the motion system accelerates and decelerates). Dynamic models of the powder delivery system motor and the powder transport system (i.e., five–meter pipe, powder dispenser, and cladding head) are first constructed. A general tracking controller is then designed to track variable powder flow rate references. Since the powder flow rate at the nozzle exit cannot be directly measured, it is estimated using the powder transport system model. The input to this model is the DC motor rotation speed, which is estimated on–line using a Kalman filter. Experiments are conducted to examine the performance of the proposed control methodology. The experimental results demonstrate that VPFRC is successful in maintaining a uniform track morphology, even when the motion control system accelerates and decelerates.Mechanical Engineerin

Investigation of the effect of consolidation on cement flow behaviour

International audienceOne of the main problems affecting the flow of cement bulk powder is the formation of cohesive arching at the outlet of the hopper, causing blockage of the silo opening and bridge formation. A simple concept is established which outlines these complications. In this context, the interactions of particles lead to a high degree of consolidation of the cement powder and an increase of adhesion force due to the small size and the large surface area of the cement particles. The results from the consolidation test and the flow properties (cohesion) show that the cement powder flow is mainly controlled by internal forces (Van der Waals and adhesion forces) and external forces. These forces have a direct influence on the powder structure, leading to a variable packing behaviour. Since the problem is attributable mainly to interparticle forces, before storage of the cement powder in the silo, the powder should be fluidised with air at a high velocity to disintegrate the cohesive structure and to overcome this undesirable property of cement flow

Analysis of rheological behaviour of titanium feedstocks formulated with a water-soluble binder system for powder injection moulding

Binder selection and formulation are critical in powder injection moulding. Binders play a key role in controlling the rheological properties of a feedstock and influence whether the resulting feedstock can be successfully injection moulded, debound and sintered without defects. A four-step process was used to mix hydride-dehydride titanium alloy (processed) powder (Ti-6Al-4 V) with a polyethylene glycol (PEG) based water soluble binder system. The rheological properties, including flow behaviour index, flow activation energy, fluidity and melt flow index of the homogeneous feedstock, were determined with a capillary rheometer. All feedstock formulations exhibited shear thinning flow behaviour. The optimum feedstock consisting of 60 vol.% powder content, 32 vol.% PEG, 6 vol.% polyvinyl butyryl and 2 vol.% stearic acid was suitable for titanium injection moulding

An Investigation of Gas-Powder Flow in Laser-Based Direct Metal Deposition

Laser-Based Direct Metal Deposition (LBDMD) is a blown-powder laser deposition process which can produce fully-dense and metallurgicaly sound parts by a layered manufacturing method. Since a deposition head equipped with discontinuous radially symmetric nozzles has the potential to be tilted without influence of the gravity on the powder stream shape, it can be used for multi-axis deposition. The shape of the gas-powder stream with respect to the shape of laser beam and the size of the molten pool, have a large influence on the size and shape of the buildup. They determine the geometrical accuracy and the surface quality of the buildup. This paper examines gas-powder flow from radially symmetric nozzles using computational fluid dynamics method. For verification purpose the powder flow was investigated by a visualization method and powder concentration distribution was analyzed using image processing technique. The obtained results are in good agreement with numerical model.Mechanical Engineerin

Method for evaluating effectiveness of dry fire-extinguishing chemicals

Apparatus used in method is commercially available, powder-deposition type oxy-acetylene torch that has been modified to provide electronically timed operations and more uniform powder flow; usual torch tips are replaced by burner head with pilot flame

Characterization and flow of food and mineral powders : a thesis presented in partial fulfillment of the requirements for the degree of Doctor of Philosophy in Engineering at Massey University, Manawatū, New Zealand

Powders are important commodities across different industries, such as the food and pharmaceutical industries. In these industries, powders are usually made, mixed, milled, packaged, and stored; these operations require the powders to move and flow under desired conditions and different stress levels. Failure to flow will cause hindrances to production; therefore knowledge of powder flow or flowability is important. There is a constant demand for accurate, reliable, and robust measurement and characterization methods for powder flowability. Powders behave differently under varying conditions; the behaviour of a powder is influenced by particle size distribution, and powder handling and processing conditions. There is to date no one “standard” method to characterize powder flowability; it is common to use a variety of methods and devices to measure flow properties and provide insight into the behaviour and flow characteristics of powders under different conditions. The flow properties of model food and mineral powders were measured and assessed by shear testing, compression via tapping, fluidization, and powder tumbling. Shear testing was done with an annular shear cell following Jenike (1964) and Berry, Bradley and McGregor (2014). Compression via tapping was performed according to a procedure in the dairy industry (Niro, 1978) and the European Pharmacopoeia (Schüssele & Bauer-Brandl, 2003). Fluidization was used to measure powder bed expansion and bed collapse following the powder classification framework provided by Geldart and co-workers (Geldart, 1973; Geldart, Harnby, & Wong, 1984; Geldart & Wong, 1984, 1985). Powder tumbling was performed in a novel Gravitational Displacement Rheometer, GDR, which measured the motion and avalanche activity of powders that moved under their own weight when rotated in a cylinder at different drum speed levels. The flow data from each characterization method were evaluated individually with regards to particle size distribution and then assessed collectively. The findings presented and discussed include the i) demonstration of the dominant influence of surface-volume mean particle diameter on powder flow properties, ii) characterization of flowability based on Jenike’s arbitrary flow divisions, iii) development of new correlations for the estimation of powder cohesion and bulk density at low preconsolidation stresses, iv) demonstration of hopper outlet diameter as a measure of flowability, v) demonstration of the limited utility of Hausner ratio as a flowability index, vi) substantiation of von Neumann ratio as a sensitive and useful indicator for identifying the onset of bubbling in fluidized beds using bed pressure fluctuation data, and vii) demonstration of the utility of standard deviation of the GDR load cell signal as an indicator of powder avalanche activity. These findings provide improved understanding and knowledge of powder flowability; they can be used to assist and facilitate the development of new techniques and solutions relevant to the handling and processing of powders especially in the food and pharmaceutical industries

Compensation for Uneven Surfaces When Building Laser Deposited Structures

Direct Laser Deposition (DLD) is a blown-powder laser deposition process that can be used to quickly produce, modify or repair fully-dense metallic parts by a layered manufacturing method. However, uneven substrate surfaces often cause variation in the deposited layer which is magnified by succeeding layers. Research carried out at the University of Liverpool has resulted in a non-feedback layer height controlling process based on controlling the shape of the powder streams emitted from a four-port side feed nozzle. This method limits deposited layer height by causing a sharp reduction of catchment efficiency in the vertical plane at a fixed distance from the powder feed nozzle, and is therefore capable of depositing a consistent layer height in spite of power, powder flow or process velocity variation. This paper demonstrates how this method of layer height control can compensate for irregular substrate surfaces in the production of accurate DLD parts.Mechanical Engineerin

Modelling powder-binder segregation in powder injection moulding

Powder injection moulding (PIM) is a shape forming technique for advance ceramic or metal that allows low cost and complex shape manufacturing. The segregation between powder and binder is a common occurrence during PIM which leads to the inhomogeneity in the green bodies. A multiphase flow numerical model has been developed based on Eulerian approach to simulate this phenomenon in the injection stage of silicon nitride-based ceramics. A viscosity model based on experimental data of the feedstock is employed in the numerical model. Simulated results from the numerical model have been compared with experimental results. A powder distribution analysis is compared with density distribution test of the green bodies with similar process parameters and flow trends is compared experimental short shots

Sensitivity Analysis of Process Parameters in Laser Deposition

In laser cladding with powder injection process, process output parameters, including melt pool temperature and melt pool dimensions, are critical for part quality. This paper uses simulation and experiments to investigate the effect of the process input parameters: laser power, powder mass flow rate, and scanning speed on the output parameters. Numerical simulations and experiments are conducted using a factorial design. The results are statistically analyzed to determine the significant factors and their interactions. The simulation results are compared to experimental results. The quantitative agreement/disagreement is discussed and further research is outlined.Mechanical Engineerin

A flow-through hydrothermal cell for in situ neutron diffraction studies of phase transformations

A flow-through hydrothermal cell for the in situ neutron diffraction study of crystallisation and phase transitions has been developed. It can be used for kinetic studies on materials that exhibit structural transformations under hydrothermal conditions. It is specifically designed for use on the medium-resolution powder diffractometer (MRPD) at ANSTO, Lucas Heights, Sydney. But it is planned to adapt the design for the Polaris beamline at ISIS and the new high-intensity powder diffractometer (Wombat) at the new Australian reactor Opal. The cell will operate in a flow-through mode over the temperature range from 25–300 1C and up to pressures of 100 bar. The first results of a successful transformation of pentlandite (Fe,Ni)9S8 to violarite (Fe,Ni)3S4 under mild conditions (pH4) at 120 1C and 3 bar using in situ neutron diffraction measurements are presented