Anomaly Detection in WAAM Deposition of Nickel Alloys: Single-Material and Cross-Material Analysis

The current research work investigates the possibility of using machine learning models to deduce the relationship between WAAM (wire arc additive manufacturing) sensor responses and defect presence in the printed part. The work specifically focuses on three materials from the nickel alloy family (Inconel 718, Invar 36 and Inconel 625) and uses three sensor responses for data analysis, which are welding voltage, welding current and welding audio. Two different machine learning models are used—artificial neural networks (ANNs) and random forests (RF). The results for each of the materials, separately, indicate that the accuracies range from 60% to 90% and the correlation coefficient is less than 0.5 (indicating weak positive correlation), depending on the model and material. In addition to separate material analysis, a cross-material data analysis was formed to test the models’ general prediction capabilities. This led to predictions that are significantly worse, with accuracies ranging from 20% to 27% and very weak correlation coefficients (less than 0.1), indicating that the choice of material is still important as a boundary condition. Analysis of the results indicates that the relative importance of audio sensor response depends on the nature of defect formation. Random forests are found to perform the best for single material analysis, with the comparatively inferior performance of ANNs possibly being due to lack of sufficient datapoints.Team Marcel Herman

Microstructure and mechanical properties of medium carbon steel deposits obtained via Wire and Arc Additive Manufacturing using metal-cored wire

Wire and arc additive manufacturing (WAAM) is a 3D metal printing technique based on the arc welding process. WAAM is considered to be suitable to produce large-scale metallic components by combining high deposition rate and low cost. WAAM uses conventional welding consumable wires as feedstock. In some applications of steel components, one-off spare parts need to be made on demand from steel grades that do not exist as commercial welding wire. In this research, a specifically produced medium carbon steel (Grade XC-45), metal-cored wire, equivalent to a composition of XC-45 forged material, was deposited with WAAM to produce a thin wall. The specific composition was chosen because it is of particular interest for the on-demand production of heavily loaded aerospace components. The microstructure, hardness, and tensile strength of the deposited part were studied. Fractography studies were conducted on the tested specimens. Due to the multiple thermal cycles during the building process, local variations in microstructural features were evident. Nevertheless, the hardness of the part was relatively uniform from the top to the bottom of the construct. The mean yield/ultimate tensile strength was 620 MPa/817 MPa in the horizontal (deposition) direction and 580 MPa/615 MPa in the vertical (build) direction, respectively. The elongation in both directions showed a significant difference, i.e., 6.4% in the horizontal direction and 11% in the vertical direction. Finally, from the dimple-like structures observed in the fractography study, a ductile fracture mode was determined. Furthermore, a comparison of mechanical properties between WAAM and traditionally processed XC-45, such as casting, forging, and cold rolling was conducted. The results show a more uniform hardness distribution and higher tensile strength of the WAAM deposit using the designed metal-cored wires.(OLD) MSE-

Optimization of adaptive metal foam arrangement in a heat storage tank

The integration of phase change materials (PCMs) and metal foam has been widely concerned recently. To decrease non-uniformity of uniform metal foam-PCMs, adaptive metal foam arrangement strategy with increasing porosity from inside to outside has attracted widespread attention. This work conducted a symmetric simulation model of vertical thermal energy storage (TES) tube validated by experiments, for optimization of adaptive metal foam arrangement in basic design (0.94–0.94–0.94). It was followed by assessing the performance of gradient metal foam structures that included 27 cases with radial foam gradients of larger porosity on the outside and smaller porosity on the inside. Results demonstrated that a smaller difference between the inside and outside subregions resulted in better thermal performance when the same porosity of the intermediate subregion was used. More intense natural convection with stronger liquid paraffin vortex could be obtained by an adaptive arrangement. With the same average porosity, the faster phase change evolution, which was influenced by the maximum promotion of stronger natural convection, was achieved by using a larger intermediate porosity and a larger porosity difference between the inside and outside regions. The optimal strategy (0.87–0.94–0.97) could significantly shorten the melting duration as maximal as 17.15% compared with the original uniform (0.94–0.94–0.94), which contributed to efficient vertical metal foam TES systems, also as light and cost-effective as possible while also avoiding sacrificing thermal capacity.Green Open Access added to TU Delft Institutional Repository 'You share, we take care!' - Taverne project https://www.openaccess.nl/en/you-share-we-take-care Otherwise as indicated in the copyright section: the publisher is the copyright holder of this work and the author uses the Dutch legislation to make this work public.Process and Energ

Identity of the catfish Liobagrus styani (Teleostei: Amblycipitidae) from Hubei Province, China

Liobagrus styani is redescribed and its identity clarified. The real L. styani is represented by the population found in the Po-He, a tributary of the lake Huanggai system in the middle Chang-Jiang basin, at Chibi City, South Hubei Province, China. The materials currently identified as L. styani from Henan, Shaanxi, Anhui and Jiangxi provinces possibly represent an undescribed species. Taxonomic and nomenclatural comments are provided for Chinese species of Liobagrus with a smooth posterior edge of the pectoral-fin spine. A key to the species of Liobagrus found in China including Taiwan Island is provided.Liobagrus styani is redescribed and its identity clarified. The real L. styani is represented by the population found in the Po-He, a tributary of the lake Huanggai system in the middle Chang-Jiang basin, at Chibi City, South Hubei Province, China. The materials currently identified as L. styani from Henan, Shaanxi, Anhui and Jiangxi provinces possibly represent an undescribed species. Taxonomic and nomenclatural comments are provided for Chinese species of Liobagrus with a smooth posterior edge of the pectoral-fin spine. A key to the species of Liobagrus found in China including Taiwan Island is provided