Evaluation and optimisation of a slurry-based layer casting process in additive manufacturing using multiphase simulations and spatial reconstruction

Slurry-based 3D printing allows ceramic green bodies to be fabricated at high packing densities. In contrast to powder-based binder jetting, full densification of printed parts can be achieved in a subsequent sintering step as fine particles dispersed in a suspension are cast and compacted. Slurry-based 3D printing is thus expected to overcome the application limits of the powder-based alternative in metal casting in terms of unfavorable properties like high surface roughness, low density and low mechanical strength. To ensure stress-free drying and therefore high qualities of the compounds made in layers, it is crucial to fabricate single layers with a high level of homogeneity. This paper presents a CFD model based on the open-source simulation environment OpenFOAM to predict the resulting homogeneity of a cast slurry layer with defined parameter sets or coater geometries using the Volume-Of-Fluid method. Moreover, a novel method of spatial reconstruction is proposed to evaluate the surface quality of layers on a minimised computional demand. By comparing the results of the simulation with the real macroscopic behaviour determined in experiments, the approach is found to be a useful tool for suggesting suitable parameters and coater geometries for processing slurries. A precise reconstruction of the outline of the coating area with different process parameters and an approximate prediction of the effect on surface roughness was achieved.

Dimensionless analysis for modelling surface finish in conventional investment casting

High level surface finish (SF) achievement is one of the major advantages of conventional investment casting process. Not much work hitherto has been reported for modeling the SF in conventional investment casting of industrial components. In the present study application of dimensionless analysis, has been made for developing a mathematical model for SF. Three input process parameters (namely: molten metal pouring temperature (PT), slurry layer’s combination (LC) and volume/surface-area (V/A) ratio of cast components) were judicially selected to give SF as output. This study provide main effects of these input parameters on SFand shed light on the SF mechanism in conventional investment casting. The comparison of mathematical model with experimental results has been made for validation of model.

Solidification of a Binary Solution (NH4Cl+H2O) under Shear Flow: A Numerical Study

In the present work, the solidification behaviour of a metal analogues transparent binary solution (8 wt% of NH4Cl in H2O) under shear flow is investigated numerically. The shear flow in the mush is developed due to flow over an inclined cooling plate. The dendrites formed during solidification are fragmented under the shear flow and transported into the bulk solution. The suspended dendrites form a slurry layer in the domain. Consequently, a suitable mathematical model is considered to study the transport phenomena. In the mathematical model, the free surface of the solution is represented by the volume-of-fluid (VOF) method. The solidification process is modelled by a set of volume-averaged-single-phase mass, momentum, energy and species conservation equations. A separate equation is considered for the solid velocity based on Stokes model. The governing equations are solved based on the pressure-based semi-implicit finite volume method according to the SIMPLER algorithm using TDMA solver along with the enthalpy update scheme. Finally, the simulation predicts temperature, velocity, solid fraction and the species distributions in the computational domain. Normal 0 false false false EN-US X-NONE X-NONE /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-priority:99; mso-style-qformat:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;}

Laser Compensation for Ceramics Accuracy Improvement of Selective Laser Sintering

This research developed a feedback control system of laser compensation for the rapid prototyping (RP) machine using layer-wise slurry deposition and selective laser sintering (SLS). The slurry was prepared by silica power and silica sol with 60 and 40 wt.% with suitable rheological properties for 0.1 mm layer deposition. Four ceramics for comparison of the formability of fabricated ceramic green parts with/without the feedback control system of laser energy density for models were designed With this laser feedback control, batter quality ceramic green parts can be manufactured and the rapid prototyping machine with steady laser energy radiated on slurry layer was achieved. Experimental results validate the well performance of the measuring laser power and feedback control system.

Fundamental Study on Setting of Diamond Abrasive Grains Using Electrostatic Force for Single-Layered Metal Bond Wheel

Single-layered metal bond diamond wheels are useful to high efficient grinding of difficult-to-grind materials because of the high gripping force of abrasive grains and the controllable grain density. In this paper, fundamental information are obtained for an application of electrostatic force to setting of diamond grains into pasted metal bond slurry layer on wheel surface, investigating experimentally jumping phenomenon of diamond grains in an electrostatic field between a electrode plate and metal bond slurry layer. The SD grains and the SDC grains coated with Ti are selected. SDC grains jump into a metal bond layer as quick as making an electrostatic field, however SD grains jump with short time lags. The setting rate of SDC grains is larger than that of SD grains, and setting position accuracy of SDC grain array is better than SD grain array. The possibility of setting abrasive grains into single-layered metal bond diamond wheel surface using electrostatic force is obtained and SDC grains are suitable to the proposed abrasive setting method.

Solids Mobilization and Suspension by Dual Opposed Mixing Pumps

Experiments were performed to support understanding mixing of Tank 241-SY-101 at the Hanford Site in Washington State. These experiments were conducted at 1/12 scale and modeled the tank and proposed mixing pump. The tests investigated solids mobilization and suspension for jets rotated in fixed increments about the tank centerline. Flow visualization tests showed that the supernatant layer was generally too cloudy for effective visualization. Observations of the settled solids interface during a start-up transient showed that the mixing action was always confined within the slurry layer. A 4.57-m/s (15-ft/s) jet velocity was not capable of clearing settled sludge off the tank floor all the way to the tank wall and produced a stratified flow field at steady state; 7.62-m/s (25-ft/s) and higher jet velocities always circulated solids to the tank surface. During the operating parameter tests with jets rotated at fixed increments, the slurry interface rose more slowly than for the fixed location jets. Solids suspension was more effective for the rotated jets than for the fixed location jets. Percent solids suspended with a 7.62-m/s (25-ft/s) jet was 66 to 72% in the high viscosity simuant and 59 to 67% in the low viscosity stimulant. Percent solids suspended with a 15.2 m/s (50-ft/s) jet was 74 to 81% in the low viscosity stimulant. A 7.62 m/s (25-ft/s) jet velocity was adequate to clear settled solids from the tank floor to the tank wall for both the low and high viscosity stimulant.

A Study for the Fabrication of Wall-Shaped Support Spacer in a Field Emission Display Panel

Using insulation slurry as composite material, the wall-shaped support spacer was designed and fabricated on the cathode back-plane. In the fabrication course of support spacer, the high effective screen-printing technique was employed to prepare the insulation slurry layer on the separation layer surface of cathode back-plane. And the conventional sintering process was utilized to solidify the printed insulation slurry layer subsequently. Many insulation slurry layers were sintered and stacked to form the support spacer arranged in equilateral triangle form. The carbon nanotube was used as field emitter, and the field emission display panel was fabricated and sealed with glass frit, which possessed good field emission characteristics and better image uniformity.