Unstructured finite volume algorithms for compressible multiphase flow

This research presents novel algorithms for computing flow within an unstructured, collocated, finite volume solver in the presence of non-orthogonality and compressibility in order to extend the range of problems which can be modelled with the University's in-house CFD code: PHYSICA. A new non-orthogonality diffusion correction relaxation parameter has been successfully introduced and tested with benchmarks from the literature. Cases involving geometries meshed with commercial packages have been successfully run with the diffusion correction methods, variable bounding and proper under-relaxation practices. The applicability of a pressure interpolation method has also been tested with these cases. A procedure for solving compressible flow within a finite volume, pressure correction type scheme, has been devised and successfully implemented in different test cases. This method is however prone to numerical diffusion in the presence of shocks, but does work even in the presence of skewed meshes. The method was then tested with the case of an oxygen jet entering a heated furnace, for which experimental data is available for comparison. The method was successful in predicting the axial variables of the jet, and used to develop a turbulence modification model for such jets. The method was finally used to model the deformation of a free surface impinged by a compressible jet, using a novel zonal method called zonal Gas And Liquid Analyser (GALA). Convergence was achieved with the method developed in this research, together with the application of the counter diffusion method to model the moving interface

Delamination influence on elastic properties of laminated composites

International audienceThe present work aims to predict the behavior of effective elastic properties for laminated composites, considering localized damage in the interface between two layers. In practical terms, the damage in the adhesion, which influences the effective elastic properties of a laminate, is evaluated like a delamination between adjacent layers. Thus, the effective properties of laminated composites with different delamination extensions are calculated via finite element method and two-scale asymptotic homogenization method. It is investigated how the properties of the laminated composites are affected by the delamination extension and the thickness of the interface between layers. It is possible to conclude that the effective coefficient values decrease as the damage extension increases due to the fact that the delamination area increases. Besides, for all effective coefficients, except the effective coefficients C * 12 , C * 13 , and C * 23 , in the case without delamination, the coefficients decrease as the adhesive region thickness increases, and almost all coefficients decrease for complete separation of the interface. Numerical and analytical results are compared in order to show the potentialities and limitations of the proposed approaches. Finally, a numerical approach is used to simulate a specific case, where the interface is considered a functionally graded material

Comparison between low-order and high-order acoustic pressure solvers for bubbly media computations

Numerical modelling is a useful tool for the fundamental study of acoustic cavitation treatment in liquid metals. This treatment, also known as ultrasonic melt processing, significantly improves the properties and quality of metallic materials. However, the mechanisms leading to these observed improvements are still unclear and a fundamental study of cavitation treatment is required to understand this process. In this endeavour, this paper compares the use of high-order discretization schemes for solving acoustic pressures in cavitating liquids with its low-order counterpart. A fourth order scheme is shown to be more stable and accurate than a second order scheme when taking into account the acceleration of bubbles before their collapse, and is recommended for the full cavitation modelling of acoustic treatment of liquid metals.UK Engineering and Physical Sciences Research Council (EPSRC

Investigation of acoustic streaming and cavitation intensity in water as an analogue for liquid metal

This paper presents an investigation of the evolution of flow structures and cavitation intensity in water as an analogue for a liquid metal under ultrasonic excitation. Results are presented for 20 kHz high-power ultrasound. The input power ranged from 50% (8.5 μm p-p) to 100% (17 μm p-p). To identify the streaming structures and understand the recirculation flows for different vibrational amplitudes of the sonotrode, particle image velocimetry (PIV) measured the velocity field. Simultaneously, a calibrated cavitometer probe measured acoustic intensity in the fluid. The cavitation intensity away from the acoustic source decreased with increasing input acoustic power, but was relatively constant inside the cavitation zone (irrespective of the input power). PIV measurements showed that the direction of the flow pattern was strongly related to the vibrational amplitude of the sonotrode. These results are compared with the predictions of an acoustic cavitation model. The outcome of the present work will help to determine the efficient optimization of ultrasonic processing of liquid metals that is of increasing technological importance

Enhancement of chip breakability of aluminium alloys by controlling the solidification during direct chill casting

Engineering and Physical Sciences Research Council (EPSRC Grant: The Future Liquid Metal Engineering Research Hub, under grant number EP/N007638/1) and Constellium, Ltd

Numerical modelling of the ultrasonic treatment of aluminium melts: An overview of recent advances

The prediction of the acoustic pressure field and associated streaming is of paramount importance to ultrasonic melt processing. Hence, the last decade has witnessed the emergence of various numerical models for predicting acoustic pressures and velocity fields in liquid metals subject to ultrasonic excitation at large amplitudes. This paper summarizes recent research, arguably the state of the art, and suggests best practice guidelines in acoustic cavitation modelling as applied to aluminium melts. We also present the remaining challenges that are to be addressed to pave the way for a reliable and complete working numerical package that can assist in scaling up this promising technology.Engineering and Physical Sciences Research Council (EPSRC), U

Effect of ultrasonic melt treatment on the sump profile and microstructure of a direct-chill cast AA6008 Aluminum Alloy

This work focuses on the effects of ultrasonic melt treatment (UST) during direct-chill (DC) casting on the temperature distribution across the billet, sump profile, and the resulting microstructure. Two AA6008 billets were cast; one was treated with UST in the hot top while the other was not. To determine the temperature distribution along the billet, multi-point temperature measurements were made across the radii of both billets. The sump profile was also analyzed through macrostructure analysis, after Zn was poured into the sump, while structure refinement was quantified through grain-size measurements. A numerical model of ultrasound-assisted DC casting is validated using the temperature measurements. As an outcome, this study provides information on the extent to which UST affects the sump profile and the corresponding changes in the microstructure. The knowledge gained from this study paves the way towards optimization of UST parameters in DC casting

Coupling of acoustic cavitation with DEM-based particle solvers for modeling de-agglomeration of particle clusters in liquid metals

The aerospace and automotive industries are seeking advanced materials with low weight yet high strength and durability. Aluminum and magnesium-based metal matrix composites with ceramic micro- and nano-reinforcements promise the desirable properties. However, larger surface-area-to-volume ratio in micro- and especially nanoparticles gives rise to van der Waals and adhesion forces that cause the particles to agglomerate in clusters. Such clusters lead to adverse effects on final properties, no longer acting as dislocation anchors but instead becoming defects. Also, agglomeration causes the particle distribution to become uneven, leading to inconsistent properties. To break up clusters, ultrasonic processing may be used via an immersed sonotrode, or alternatively via electromagnetic vibration. This paper combines a fundamental study of acoustic cavitation in liquid aluminum with a study of the interaction forces causing particles to agglomerate, as well as mechanisms of cluster breakup. A non-linear acoustic cavitation model utilizing pressure waves produced by an immersed horn is presented, and then applied to cavitation in liquid aluminum. Physical quantities related to fluid flow and quantities specific to the cavitation solver are passed to a discrete element method particles model. The coupled system is then used for a detailed study of clusters’ breakup by cavitation

Numerical modelling of ultrasonic waves in a bubbly Newtonian liquid using a high-order acoustic cavitation model

To address difficulties in treating large volumes of liquid metal with ultrasound, a fundamental study of acoustic cavitation in liquid aluminium, expressed in an experimentally validated numerical model, is presented in this paper. To improve the understanding of the cavitation process, a non-linear acoustic model is validated against reference water pressure measurements from acoustic waves produced by an immersed horn. A high-order method is used to discretize the wave equation in both space and time. These discretized equations are coupled to the Rayleigh-Plesset equation using two different time scales to couple the bubble and flow scales, resulting in a stable, fast, and reasonably accurate method for the prediction of acoustic pressures in cavitating liquids. This method is then applied to the context of treatment of liquid aluminium, where it predicts that the most intense cavitation activity is localised below the vibrating horn and estimates the acoustic decay below the sonotrode with reasonable qualitative agreement with experimental data.The authors are grateful to the UK Engineering and Physical Sciences Research Council (EPSRC) for financial assistance for this research in contract numbers EP/K00588X/1 and EP/K005804/1. A representative sample of research data is provided in supplementary data at gala.gre.ac.uk. The underlying raw data is not shared online due to its size