Effect of Geometrical Modeling on the Prediction of Laser-Induced Heat Transfer in Metal Foam

2016 ◽  
Vol 138 (12) ◽  
Author(s):  
Tizian Bucher ◽  
Christopher Bolger ◽  
Min Zhang ◽  
Chang Jun Chen ◽  
Y. Lawrence Yao
Keyword(s):  
Experimental Data ◽  
Metal Foam ◽  
Numerical Models ◽  
Temperature Response ◽  
Infrared Camera ◽  
Industrial Applications ◽  
Laser Forming ◽  
Transient Temperature ◽  
Al Foam ◽  
Mechanical Bending

Over the past several decades, aluminum foam (Al-foam) has found increasing popularity in industrial applications due to its unique material properties. Unfortunately, till date Al-foam can only be affordably manufactured in flat panels, and it becomes necessary to bend the foam to the final shape that is required in engineering applications. Past studies have shown that thin cell walls crack and collapse when conventional mechanical bending methods are used. Laser forming, on the other hand, was shown to be able to bend the material without causing fractures and cell collapse. This study was focused on the thermal aspects of laser forming of closed-cell Al-foam. An infrared camera was used to measure the transient temperature response of Al-foam to stationary and moving laser sources. Moreover, three different numerical models were developed to determine how much geometrical accuracy is needed to obtain a good agreement with experimental data. Different levels of geometrical complexity were used, including a simple solid geometry, a Kelvin-cell based geometry, and a highly accurate porous geometry that was based on an X-ray computed tomography (CT) scan. The numerical results were validated with the experimental data, and the performances of the numerical models were compared.

Laser Forming of Metal Foam Sandwich Panels: Effect of Panel Manufacturing Method

2019 ◽  
Vol 141 (5) ◽  
Author(s):  
Tizian Bucher ◽  
Min Zhang ◽  
Chang Jun Chen ◽  
Ravi Verma ◽  
Wayne Li ◽  
...  
Keyword(s):  
Metal Foam ◽  
Numerical Models ◽  
Sandwich Panels ◽  
Weight Ratio ◽  
Industrial Applications ◽  
Laser Forming ◽  
Process Conditions ◽  
Foam Core ◽  
Wide Range ◽  
The Impact

Sandwich panels with metal foam cores have a tremendous potential in various industrial applications due to their outstanding strength-to-weight ratio, stiffness, and shock absorption capacity. A recent study paved the road toward a more economical implementation of sandwich panels, by showing that the material can be successfully bent up to large angles using laser forming. The study also developed a fundamental understanding of the underlying bending mechanisms and established accurate numerical models. In this study, these efforts were carried further, and the impact of the foam core structure, the facesheet and foam core compositions, and the adhesion method on the bending efficiency and the bending limit was investigated. These factors were studied individually and collectively by comparing two fundamentally different sandwich panel types. Thermally induced stresses at the facesheet/core interface were thoroughly considered. Numerical modeling was carried out under different levels of geometric accuracy to complement bending experiments under a wide range of process conditions. Interactions between panel properties and process conditions were demonstrated and discussed.

Laser Forming of Metal Foam Sandwich Panels: Effect of Panel Manufacturing Method

2019 ◽  
Author(s):  
Tizian Bucher ◽  
Min Zhang ◽  
Chang Jun Chen ◽  
Ravi Verma ◽  
Wayne Li ◽  
...  
Keyword(s):  
Metal Foam ◽  
Numerical Models ◽  
Sandwich Panels ◽  
Weight Ratio ◽  
Industrial Applications ◽  
Laser Forming ◽  
Process Conditions ◽  
Foam Core ◽  
Wide Range ◽  
The Impact

Abstract Sandwich panels with metal foam cores have a tremendous potential in various industrial applications due to their outstanding strength-to-weight ratio, stiffness, and shock absorption capacity. A recent study paved the road towards a more economical implementation of sandwich panels, by showing that the material can be successfully bent up to large angles using laser forming. The study also developed a fundamental understanding of the underlying bending mechanisms and established accurate numerical models. In this study, these efforts were carried further, and the impact of the foam core structure, the facesheet and foam core compositions, as well as the adhesion method on the bending efficiency and bending limit was investigated. These factors were studied individually and collectively by comparing two fundamentally different sandwich panel types. Thermally-induced stresses at the facesheet/core interface were thoroughly considered. Numerical modeling was carried out under different levels of geometric accuracy, to complement bending experiments under a wide range of process conditions. Interactions between panel properties and process conditions were demonstrated and discussed.

Bending Mechanism Analysis for Laser Forming of Metal Foam

2017 ◽  
Author(s):  
Tizian Bucher ◽  
Adelaide Young ◽  
Min Zhang ◽  
Chang Jun Chen ◽  
Y. Lawrence Yao
Keyword(s):  
Temperature Gradient ◽  
Sheet Metal ◽  
Metal Foam ◽  
Numerical Models ◽  
Image Correlation ◽  
Laser Forming ◽  
Mechanism Analysis ◽  
Forming Process ◽  
Experimental Proof ◽  
Post Process

To date, the industrial production of metal foam components has remained challenging, since few methods exist to manufacture metal foam into the shapes required in engineering applications. Laser forming is currently the only method with a high geometrical flexibility that is able to shape arbitrarily sized parts. What prevents the industrial implementation of the method, however, is that no detailed experimental analysis has been done of the metal foam strain response during laser forming, and hence the existing numerical models have been insufficiently validated. Moreover, current understanding of the laser forming process is poor, and it has been assumed, without experimental proof, that the temperature gradient mechanism (TGM) from sheet metal forming is the governing mechanism for metal foam. In this study, these issues were addressed by using digital image correlation (DIC) to obtain in-process and post-process strain data that was then used to validate a numerical model. Additionally, metal foam laser forming was compared with metal foam 4-point bending and sheet metal laser forming to explain why metal foam can be bent despite its high bending stiffness, and to evaluate whether TGM is valid for metal foam. The strain measurements revealed that tensile stretching is only a small contributor to foam bending, with the major contributor being compression-induced shortening. Unlike in sheet metal laser forming, this shortening is achieved through cell wall bending, as opposed to plastic compressive strains. Based on this important difference with traditional TGM, a modified temperature gradient mechanism (MTGM) was proposed.

Identifying Physico-Chemical Laws from the Robotically Collected Data

2019 ◽  
Author(s):  
Liwei Cao ◽  
Danilo Russo ◽  
Vassilios S. Vassiliadis ◽  
Alexei Lapkin
Keyword(s):  
Experimental Data ◽  
Numerical Models ◽  
Predictor Variable ◽  
Physical Models ◽  
Training Data ◽  
Mixed Integer ◽  
Physico Chemical ◽  
Data Points ◽  
Future Work ◽  
The Relationship

<p>A mixed-integer nonlinear programming (MINLP) formulation for symbolic regression was proposed to identify physical models from noisy experimental data. The formulation was tested using numerical models and was found to be more efficient than the previous literature example with respect to the number of predictor variables and training data points. The globally optimal search was extended to identify physical models and to cope with noise in the experimental data predictor variable. The methodology was coupled with the collection of experimental data in an automated fashion, and was proven to be successful in identifying the correct physical models describing the relationship between the shear stress and shear rate for both Newtonian and non-Newtonian fluids, and simple kinetic laws of reactions. Future work will focus on addressing the limitations of the formulation presented in this work, by extending it to be able to address larger complex physical models.</p><p><br></p>

Experimental and Theoretical Analysis of Transient Response of Plate Heat Exchangers in Presence of Nonuniform Flow Distribution

2008 ◽  
Vol 130 (5) ◽  
Author(s):  
N. Srihari ◽  
Sarit K. Das
Keyword(s):  
Steady State ◽  
Heat Exchangers ◽  
Sudden Change ◽  
Temperature Response ◽  
Flow Distribution ◽  
Transient Temperature ◽  
Nonuniform Flow ◽  
Flow Rates ◽  
Plate Heat ◽  
Flow Maldistribution

Transient analysis helps us to predict the behavior of heat exchangers subjected to various operational disturbances due to sudden change in temperature or flow rates of the working fluids. The present experimental analysis deals with the effect of flow distribution on the transient temperature response for U-type and Z-type plate heat exchangers. The experiments have been carried out with uniform and nonuniform flow distributions for various flow rates. The temperature responses are analyzed for various transient characteristics, such as initial delay and time constant. It is also possible to observe the steady state characteristics after the responses reach asymptotic values. The experimental observations indicate that the Z-type flow configuration is more strongly affected by flow maldistribution compared to the U-type in both transient and steady state regimes. The comparison of the experimental results with numerical solution indicates that it is necessary to treat the flow maldistribution separately from axial thermal dispersion during modeling of plate heat exchanger dynamics.

Microstructure Integrated Modeling of Multiscan Laser Forming

2002 ◽  
Vol 124 (2) ◽  
pp. 379-388 ◽  
Author(s):  
Jin Cheng ◽  
Y. Lawrence Yao
Keyword(s):  
Flow Stress ◽  
Numerical Models ◽  
Flow Behavior ◽  
Fem Simulation ◽  
Constitutive Models ◽  
Low Carbon Steel ◽  
Laser Forming ◽  
Low Carbon ◽  
Forming Process ◽  
Heating And Cooling

Laser forming of steel is a hot forming process with high heating and cooling rate, during which strain hardening, dynamic recrystallization, and phase transformation take place. Numerical models considering strain rate and temperature effects only usually give unsatisfactory results when applied to multiscan laser forming operations. This is mainly due to the inadequate constitutive models employed to describe the hot flow behavior. In this work, this limitation is overcome by considering the effects of microstructure change on the flow stress in laser forming processes of low carbon steel. The incorporation of such flow stress models with thermal mechanical FEM simulation increases numerical model accuracy in predicting geometry change and mechanical properties.

scholarly journals Transient Infrared Measurement of Laser Absorption Properties of Porous Materials

2016 ◽  
Vol 16 (3) ◽  
pp. 167-173
Author(s):  
Andrzej Marynowicz
Keyword(s):  
Laser Beam ◽  
Building Materials ◽  
Optimization Technique ◽  
Infrared Camera ◽  
Transient Temperature ◽  
Absorption Properties ◽  
Porous Building Materials ◽  
Laser Absorption ◽  
Infrared Measurement ◽  
Heating Up

Abstract The infrared thermography measurements of porous building materials have become more frequent in recent years. Many accompanying techniques for the thermal field generation have been developed, including one based on laser radiation. This work presents a simple optimization technique for estimation of the laser beam absorption for selected porous building materials, namely clinker brick and cement mortar. The transient temperature measurements were performed with the use of infrared camera during laser-induced heating-up of the samples’ surfaces. As the results, the absorbed fractions of the incident laser beam together with its shape parameter are reported.

Leakage Flow Investigations on a Through-Wall Crack Related to Thermal Fatigue of Nuclear Power Plant Piping

2017 ◽  
Author(s):  
Stefan Schmid ◽  
Rudi Kulenovic ◽  
Eckart Laurien
Keyword(s):  
Experimental Data ◽  
Nuclear Power ◽  
Numerical Models ◽  
Measurement Techniques ◽  
Experimental Investigations ◽  
Leakage Flow ◽  
Test Rig ◽  
Reduced Pressure ◽  
Flow Rates ◽  
Set Up

For the validation of empirical models to calculate leakage flow rates in through-wall cracks of piping, reliable experimental data are essential. In this context, the Leakage Flow (LF) test rig was built up at the IKE for measurements of leakage flow rates with reduced pressure (maximum 1 MPA) and temperature (maximum 170 °C) compared to real plant conditions. The design of the test rig enables experimental investigations of through-wall cracks with different geometries and orientations by means of circular blank sheets with integrated cracks which are installed in the tubular test section of the test rig. In the paper, the experimental LF set-up and used measurement techniques are explained in detail. Furthermore, first leakage flow measurement results for one through-wall crack geometry and different imposed fluid pressures at ambient temperature conditions are presented and discussed. As an additional aspect the experimental data are used for the determination of the flow resistance of the investigated leak channel. Finally, the experimental results are compared with numerical results of WinLeck calculations to prove specifically in WinLeck implemented numerical models.

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