CFD Modeling of Laser Guided Deposition for Direct Write Fabrication

2000 ◽  
Vol 624 ◽  
Author(s):  
J. C. Sheu ◽  
M. G. Giridharan ◽  
S. Lowry
Keyword(s):  
Particle Deposition ◽  
Laser Intensity ◽  
Ambient Pressure ◽  
Ambient Air ◽  
Deposition Process ◽  
Traverse Speed ◽  
Operating Conditions ◽  
Cfd Modeling ◽  
Direct Write ◽  
Fully Coupled

ABSTRACTA computational model for simulating laser-guided particle deposition process is described. This model solves for the transport of gas and particle phases in a fully coupled manner. The optical forces on the particles are evaluated from Mie theory based on local laser intensity. Simulations were performed for different operating conditions of laser power, ambient pressure, and substrate traverse speed. Simulations revealed potential problems such as particle deflected away from substrate due to ambient air current disturbances, substrate overheating, and optical fiber clogging. Possible solutions for these problems are discussed

Structure of Airblast Sprays Under High Ambient Pressure Conditions

1997 ◽  
Vol 119 (3) ◽  
pp. 512-518 ◽  
Author(s):  
Q. P. Zheng ◽  
A. K. Jasuja ◽  
A. H. Lefebvre
Keyword(s):  
Ambient Pressure ◽  
Laser Sheet ◽  
Cone Angle ◽  
Ambient Air ◽  
Operating Conditions ◽  
Air Pressure ◽  
Spray Cone Angle ◽  
Spray Cone ◽  
Spray Volume ◽  
Drop Size Distributions

A single-velocity-component phase Doppler particle analyzer is used to survey and measure local variations in drop-size distributions and drop velocities in the nearnozzle region of a practical, contraswirling, prefilming airblast atomizer. The technique of laser sheet imaging is used to obtain global patterns of the spray. All measurements are taken with a constant pressure drop across the atomizer of 5 percent, at ambient air pressures of 1, 6, and 12 bar. The liquid employed is aviation kerosine at flow rates up to 75 g/s. The results show that increasing the air pressure from 1 to 12 bar at a constant air/fuel ratio causes the initial spray cone angle to widen from 70 to 105 deg. Farther downstream the spray volume remains largely unaffected by variations in atomizer operating conditions. However, the radial distribution of fuel within the spray volume is such that increases in fuel flow rate cause a larger proportion of fuel to be contained in the outer regions of the spray. The effect of ambient pressure on the overall Sauter mean diameter is small. This is attributed to the fact that the rapid disintegration of the fuel sheet produced by the contraswirling air streams ensures that the atomization process is dominated by the “prompt” mechanism. For this mode of liquid breakup, theory predicts that mean drop sizes are independent of air pressure.

Experimental and Computational Studies of Particle Scavenge Flow in Direct Laser Metal Sintering

2019 ◽  
Author(s):  
Morgan Austin ◽  
Thao Tran-Le ◽  
Robert Kunz ◽  
Timothy Simpson ◽  
Rui Ni
Keyword(s):  
High Speed ◽  
Particle Deposition ◽  
Single Phase ◽  
Cross Flow ◽  
Operating Conditions ◽  
Cfd Modeling ◽  
Phase Measurements ◽  
Direct Laser ◽  
Flow Systems ◽  
Lift Off

Abstract Powder Bed Fusion (PBF) cross-flow systems are designed to flow gas across the build plane and entrain metallic powder particles that are ejected during the build, due to the thermal and attendant released kinetic energy of the laser melt process. It is important that these particles be removed from the build chamber so that they do not redeposit on the build surface, as this uncontrolled particle deposition can degrade the part quality. Optimal design of these sub-systems involves tailoring a cross-flow jet such that most of the ejected particles are entrained and removed from the build chamber, while the top layer of particles that are freshly spread on the build plate are not entrained. Accordingly, a combined experimental and CFD study has been executed with the goal of developing engineering design guidance for these cross-flow systems. The closed loop small footprint wind tunnel incorporates a 0.305 m × 0.305 m × 0.915 m test section, a variable height build plate upon which powder can be spread, a variable geometry inlet nozzle, and variable flow rate so that a variety of cross-flow configurations can be tested. Helium bubble particle tracking velocimetry (PTV) was used to characterize the single-phase flow at a number of these operating conditions / configurations. In addition, high speed videography was used to study particle liftoff and entrainment at these same conditions. Using these measurements and attendant CFD models, critical particle liftoff Shield numbers were obtained using CFD predictions of friction velocity. Specifically, close agreement between CFD and measurements were obtained, so that predicted Shields numbers, Sh, could be correlated with particle Reynolds number, Reτ. In this paper we present details of the experimental facility and test program, experimental results including uncertainty/error analysis for the PTV measurements, as well as the videography results for an aluminum alloy powder. The results of the CFD modeling are compared to the single phase measurements. Since very good agreement is observed, predicted wall-shear stress values are used to estimate Sh vs. Reτ at flow rates where incipient particle lift-off is observed experimentally.

scholarly journals CFD Modeling Analysis of Mechanical Draft Cooling Tower

2008 ◽  
Author(s):  
Si Y. Lee ◽  
James S. Bollinger ◽  
Alfred J. Garrett ◽  
Larry D. Koffman
Keyword(s):  
Water Droplet ◽  
Cooling Tower ◽  
Waste Heat ◽  
National Laboratory ◽  
Ambient Air ◽  
Operating Conditions ◽  
Cfd Modeling ◽  
Test Results ◽  
Savannah River ◽  
The Impact

Industrial processes use mechanical draft cooling towers (MDCT’s) to dissipate waste heat by transferring heat from water to air via evaporative cooling, which causes air humidification. The Savannah River Site (SRS) has a MDCT consisting of four independent compartments called cells. Each cell has its own fan to help maximize heat transfer between ambient air and circulated water. The primary objective of the work is to conduct a parametric study for cooling tower performance under different fan speeds and ambient air conditions. The Savannah River National Laboratory (SRNL) developed a computational fluid dynamics (CFD) model to achieve the objective. The model uses three-dimensional momentum, energy, continuity equations, air-vapor species balance equation, and two-equation turbulence as the basic governing equations. It was assumed that vapor phase is always transported by the continuous air phase with no slip velocity. In this case, water droplet component was considered as discrete phase for the interfacial heat and mass transfer via Lagrangian approach. Thus, the air-vapor mixture model with discrete water droplet phase is used for the analysis. A series of the modeling calculations was performed to investigate the impact of ambient and operating conditions on the thermal performance of the cooling tower when fans were operating and when they were turned off. The model was benchmarked against the literature data and the SRS test results for key parameters such as air temperature and humidity at the tower exit and water temperature for given ambient conditions. Detailed modeling and test results will be presented here.

Structure of Airblast Sprays Under High Ambient Pressure Conditions

1996 ◽  
Author(s):  
Q. P. Zheng ◽  
A. K. Jasuja ◽  
A. H. Lefebvre
Keyword(s):  
Ambient Pressure ◽  
Laser Sheet ◽  
Cone Angle ◽  
Ambient Air ◽  
Operating Conditions ◽  
Air Pressure ◽  
Spray Cone Angle ◽  
Spray Cone ◽  
Spray Volume ◽  
Drop Size Distributions

A single-velocity-component Phase Doppler Particle Analyzer is used to survey and measure local variations in drop-size distributions and drop velocities in the near-nozzle region of a practical, contra-swirling, prefilming airblast atomizer. The technique of Laser Sheet Imaging is used to obtain global patterns of the spray. All measurements are taken with a constant pressure drop across the atomizer of 5 percent, at ambient air pressures of 1, 6 and 12 bar. The liquid employed is aviation kerosine at flow rates up to 75 g/s. The results show that increasing the air pressure from 1 to 12 bar at a constant air/fuel ratio causes the initial spray cone angle to widen from 85° to 105°. Further downstream the spray volume remains largely unaffected by variations in atomizer operating conditions. However, the radial distribution of fuel within the spray volume is such that increases in fuel flow rate cause a larger proportion of fuel to be contained in the outer regions of the spray. The effect of ambient pressure on the overall Sauter mean diameter is small. This is attributed to the fact that the rapid disintegration of the fuel sheet produced by the contra-swirling air streams ensures that the atomization process is dominated by the ‘prompt’ mechanism. For this mode of liquid breakup, theory predicts that mean drop sizes are independent of air pressure.

Unsteady simulations of migration and deposition of fly-ash particles in the first-stage turbine of an aero-engine

2021 ◽  
pp. 1-21
Author(s):  
Z. Hao ◽  
X. Yang ◽  
Z. Feng
Keyword(s):  
Fly Ash ◽  
Film Cooling ◽  
Particle Deposition ◽  
Flow Characteristics ◽  
Leading Edge ◽  
Velocity Model ◽  
Operating Conditions ◽  
Inlet Temperature ◽  
Internal Cooling ◽  
Aero Engine

Abstract Particulate deposits in aero-engine turbines change the profile of blades, increase the blade surface roughness and block internal cooling channels and film cooling holes, which generally leads to the degradation of aerodynamic and cooling performance. To reveal particle deposition effects in the turbine, unsteady simulations were performed by investigating the migration patterns and deposition characteristics of the particle contaminant in a one-stage, high-pressure turbine of an aero-engine. Two typical operating conditions of the aero-engine, i.e. high-temperature take-off and economic cruise, were discussed, and the effects of particle size on the migration and deposition of fly-ash particles were demonstrated. A critical velocity model was applied to predict particle deposition. Comparisons between the stator and rotor were made by presenting the concentration and trajectory of the particles and the resulting deposition patterns on the aerofoil surfaces. Results show that the migration and deposition of the particles in the stator passage is dominated by the flow characteristics of fluid and the property of particles. In the subsequential rotor passage, in addition to these factors, particles are also affected by the stator–rotor interaction and the interference between rotors. With higher inlet temperature and larger diameter of the particle, the quantity of deposits increases and the deposition is distributed mainly on the Pressure Side (PS) and the Leading Edge (LE) of the aerofoil.

scholarly journals SARS-CoV-2-Laden Respiratory Aerosol Deposition in the Lung Alveolar-Interstitial Region Is a Potential Risk Factor for Severe Disease: A Modeling Study

2021 ◽  
Vol 11 (5) ◽  
pp. 431
Author(s):  
Sabine Hofer ◽  
Norbert Hofstätter ◽  
Albert Duschl ◽  
Martin Himly
Keyword(s):  
Risk Factor ◽  
Particle Deposition ◽  
Early Stage ◽  
Severe Disease ◽  
Ambient Air ◽  
Aerosol Deposition ◽  
Pulmonary Involvement ◽  
Mild Disease ◽  
Disease Initiation

COVID-19, predominantly a mild disease, is associated with more severe clinical manifestation upon pulmonary involvement. Virion-laden aerosols and droplets target different anatomical sites for deposition. Compared to droplets, aerosols more readily advance into the peripheral lung. We performed in silico modeling to confirm the secondary pulmonary lobules as the primary site of disease initiation. By taking different anatomical aerosol origins into consideration and reflecting aerosols from exhalation maneuvers breathing and vocalization, the physicochemical properties of generated respiratory aerosol particles were defined upon conversion to droplet nuclei by evaporation at ambient air. To provide detailed, spatially-resolved information on particle deposition in the thoracic region of the lung, a top-down refinement approach was employed. Our study presents evidence for hot spots of aerosol deposition in lung generations beyond the terminal bronchiole, with a maximum in the secondary pulmonary lobules and a high preference to the lower lobes of both lungs. In vivo, initial chest CT anomalies, the ground glass opacities, resulting from partial alveolar filling and interstitial thickening in the secondary pulmonary lobules, are likewise localized in these lung generations, with the highest frequency in both lower lobes and in the early stage of disease. Hence, our results suggest a disease initiation right there upon inhalation of virion-laden respiratory aerosols, linking the aerosol transmission route to pathogenesis associated with higher disease burden and identifying aerosol transmission as a new independent risk factor for developing a pulmonary phase with a severe outcome.

scholarly journals Design of Molecular Water Oxidation Catalysts Stabilized by Ultrathin Inorganic Overlayers—Is Active Site Protection Necessary?

Inorganics ◽  
2018 ◽  
Vol 6 (4) ◽  
pp. 105 ◽  
Author(s):  
Laurent Sévery ◽  
Sebastian Siol ◽  
S. Tilley
Keyword(s):  
Water Oxidation ◽  
Atomic Layer ◽  
Deposition Process ◽  
Operating Conditions ◽  
Molecular Water ◽  
Side Reactions ◽  
Aqueous Environment ◽  
Oxidation Catalysts ◽  
Initial Onset ◽  
Anchoring Groups

Anchored molecular catalysts provide a good step towards bridging the gap between homogeneous and heterogeneous catalysis. However, applications in an aqueous environment pose a serious challenge to anchoring groups in terms of stability. Ultrathin overlayers embedding these catalysts on the surface using atomic layer deposition (ALD) are an elegant solution to tackle the anchoring group instability. The propensity of ALD precursors to react with water leads to the question whether molecules containing aqua ligands, such as most water oxidation complexes, can be protected without side reactions and deactivation during the deposition process. We synthesized two iridium and two ruthenium-based water oxidation catalysts, which contained an aqua ligand (Ir–OH2 and Ru–OH2) or a chloride (Ir–Cl and Ru–Cl) that served as a protecting group for the former. Using a ligand exchange reaction on the anchored and partially embedded Ru–Cl, the optimal overlayer thickness was determined to be 1.6 nm. An electrochemical test of the protected catalysts on meso-ITO showed different behaviors for the Ru and the Ir catalysts. The former showed no onset difference between protected and non-protected versions, but limited stability. Ir–Cl displayed excellent stability, whilst the unprotected catalyst Ir–OH2 showed a later initial onset. Self-regeneration of the catalytic activity of Ir–OH2 under operating conditions was observed. We propose chloride ligands as generally applicable protecting groups for catalysts that are to be stabilized on surfaces using ALD.

Ambient Condition Effects on NOx and CO Emissions From Process Heaters

2008 ◽  
Author(s):  
Wesley R. Bussman ◽  
Charles E. Baukal
Keyword(s):  
Atmospheric Pressure ◽  
Ambient Air ◽  
Operating Conditions ◽  
Nox Emissions ◽  
Ambient Conditions ◽  
Fuel Gas ◽  
Natural Draft ◽  
Actual Operating ◽  
Wide Range ◽  
Pollution Emissions

Because process heaters are typically located outside, their operation is subject to the weather. Heaters are typically tuned at a given set of conditions; however, the actual operating conditions may vary dramatically from season to season and sometimes even within a given day. Wind, ambient air temperature, ambient air humidity, and atmospheric pressure can all significantly impact the O2 level, which impacts both the thermal efficiency and the pollution emissions from a process heater. Unfortunately, most natural draft process burners are manually controlled on an infrequent basis. This paper shows how changing ambient conditions can considerably impact both CO and NOx emissions if proper adjustments are not made as the ambient conditions change. Data will be presented for a wide range of operating conditions to show how much the CO and NOx emissions can be affected by changes in the ambient conditions for fuel gas fired natural draft process heaters, which are the most common type used in the hydrocarbon and petrochemical industries. Some type of automated burner control, which is virtually non-existent today in this application, is recommended to adjust for the variations in ambient conditions.

Modelling Strategies for Large-Eddy Simulation of Lean Burn Spray Flames

2017 ◽  
Author(s):  
S. Puggelli ◽  
D. Bertini ◽  
L. Mazzei ◽  
A. Andreini
Keyword(s):  
Large Eddy Simulation ◽  
Ambient Pressure ◽  
Nox Reduction ◽  
Operating Conditions ◽  
Pollutant Emissions ◽  
Lean Burn ◽  
Eddy Simulation ◽  
Flamelet Generated Manifold ◽  
Large Eddy ◽  
Modelling Strategies

During the last years aero-engines are progressively evolving toward design concepts that permit improvements in terms of engine safety, fuel economy and pollutant emissions. With the aim of satisfying the strict NOx reduction targets imposed by ICAO-CAEP, lean burn technology is one of the most promising solutions even if it must face safety concerns and technical issues. Hence a depth insight on lean burn combustion is required and Computational Fluid Dynamics (CFD) can be a useful tool for this purpose. In this work a comparison in Large-Eddy Simulation (LES) framework of two widely employed combustion approaches like the Artificially Thickened Flame (ATF) and the Flamelet Generated Manifold (FGM) is performed using ANSYS® Fluent v16.2. Two literature test cases with increasing complexity in terms of geometry, flow field and operating conditions are considered. Firstly, capabilities of FGM are evaluated on a single swirler burner operating at ambient pressure with a standard pressure atomizer for spray injection. Then a second test case, operated at 4 bar, is simulated. Here kerosene fuel is burned after an injection through a prefilming airblast atomizer within a co-rotating double swirler. Obtained comparisons with experimental results show the different capabilities of ATF and FGM in modelling the partially-premixed behaviour of the flame and provides an overview of the main strengths and limitations of the modelling strategies under investigation.

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