Enhanced Material, Parts Optimization and Process Intensification (Lecture Notes in Mechanical Engineering)

✍ Scribed by Uwe Reisgen (editor), Dietmar Drummer (editor), Holger Marschall (editor)

• Publisher: Springer
• Year: 2021
• Tongue: English
• Leaves: 288
• Category: Library

✦ Synopsis

This book reports on topics at the interface between material processing, product and process optimization. It covers new developments and challenges in welding, brazing, cutting and coating, casting and molding, additive manufacturing, simulation and optimization techniques, as well as functional and structural materials and composites. Gathering authoritative contributions on the latest research and applications, presented at the International Joint Conference on Enhanced Material and Part Optimization and Process Intensification, EMPOrIA 2020, organized by SFB1120 Aachen, SFB814 Erlangen and CCE Darmstadt, on May 19–20, 2020, in Aachen, this book provides academics, students, and professionals with a timely snapshot of the main research trends, and extensive information on cutting-edge methods and technologies in materials, manufacturing and process engineering.

✦ Table of Contents

Preface
Organization
Steering Committee
General Chair
Co-chairs
Members
Program Committee
EMPOrIA Team
Contents
Welding
Simulation of Phase Transformation and Residual Stress of Low Alloy Steel in Laser Beam Welding
1 Introduction
2 State of the Art
3 Welding Trials
4 Numerical Simulation Model
4.1 Heat Source Model
4.2 Phase Transformation Model
5 Results and Discussion
References
Metallographic Comparison for Laser Welding of Cu-ETP and CuSn6 with Laser Beam Sources of 515 nm and 1030 nm Wavelength
1 Introduction
2 State of the Art
2.1 Laser Micro Welding
3 Modeling and Experimental Setup
4 Results and Discussion
5 Conclusions and Outlook
References
Numerical Investigation of Keyhole Depth Formation in Micro Welding of Copper with 1030 nm and 515 nm Laser Radiation
1 Introduction
2 Mathematical Modeling
2.1 Layer Model and Model Parameters
2.2 Conditional Equations
2.3 Absorbed Heat Flux
2.4 Limitations
3 Simulation Results
3.1 Simulation Parameters
3.2 Calculation Results
4 Discussion
4.1 Keyhole Depth Sensitivities
4.2 Mechanisms of Keyhole Depth Formation
5 Conclusion
References
Reduction of Hot Cracks During Electron Beam Welding of Alloy-247 LC
1 Introduction
2 Experimental Setup
2.1 Material
2.2 Process
2.3 Evaluation Methods
3 Results
3.1 Influence of the Welding Speed on the Welding Depth
3.2 Influence of the Welding Speed on the Dendrite Morphology
3.3 Crack Formation Depending on the Welding Speed
3.4 Welding of Creep Specimens
4 Conclusion
References
Validation of the EDACC Model for GMAW Process Simulation by Weld Pool Dimension Comparison
1 Introduction
2 Methods
2.1 Geometrical Data
2.2 Heat Source Calibration Data
3 Results
3.1 Quantitative Comparison
3.2 Qualitative Comparison
4 Discussion
5 Conclusion
References
Brazing
New Opportunities for Brazing Research by in situ Experiments in a Large Chamber Scanning Electron Microscope
1 Introduction
2 Focus Application: in situ Brazing
2.1 Experimental
2.2 Results
2.3 Discussion and Conclusions
References
Phase-Field Modeling of Precipitation Microstructure Evolution in Multicomponent Alloys During Industrial Heat Treatments
1 Introduction
1.1 Precipitation Microstructure Evolution
1.2 Phase-Field Simulations of Precipitate Microstructure Evolution
2 Results and Discussion
2.1 Simulation of Aging in René 80
2.2 Precipitation Within an Extended Braze Gap
3 Conclusion
References
Coating
TiOx/Cr2O3 Heating Coatings for Injection Molding of Polyamide
1 Introduction
2 Materials and Methods
3 Results and Discussion
4 Conclusion
References
Simulation of Multiple Particle Impacts in Plasma Spraying
1 Introduction
2 Numerical Modelling
2.1 Model Validation
2.2 Simulation Setup
3 Results and Discussion
4 Conclusion and Outlook
References
Simplex Space-Time Meshes for Droplet Impact Dynamics
1 Introduction
2 Governing Equations of Axisymmetric Two-Phase Flows
3 Results
3.1 Static Droplet on a Solid Surface
3.2 Impact of a Water Droplet on a Solid Surface
4 Conclusion
References
Additive Manufacturing
Melt Pool Formation and Out-of-Equilibrium Solidification During the Laser Metal Deposition Process
1 Introduction
1.1 Approach
2 From Process Parameters to Solidification Conditions
2.1 Melt Pool Modelling
2.2 Melt Pool Model Validation and Influence of Volume Energy
2.3 Determination of Solidification Conditions
3 From Solidification Conditions to Microstructure
3.1 Microstructure Modelling
3.2 Comparison with Experimental Data
4 Discussion and Outlook
References
Understanding Cylinder Temperature Effects in Laser Beam Melting of Polymers
1 Introduction
2 State of the Art
3 Materials and Methods
3.1 Material System
3.2 Laser Beam Melting System
3.3 Fabrication Experiments
3.4 Temperature Measurements
3.5 Thermal Simulation
3.6 Material and Part Characterization
4 Results and Discussion
5 Summary and Outlook
References
Additive Manufacturing of Multi-material Polymer Parts Within the Collaborative Research Center 814
1 Introduction
2 State of the Art – Additive Manufacturing of Multi-material-Parts
3 Multi-material Concepts Within the CRC 814
3.1 Multi-material powder deposition
3.2 Implementation of Reactive Liquids in the Laser Sintering Process
4 Experimental Methodology
4.1 Nozzle-Based Multi-material Deposition
4.2 Electrophotographic Patterned Powder Layer Preparation
4.3 Generation and Analysis of Multi-material Parts
4.4 Dynamic Mechanical Properties of Resin Infused Polymer Powder Specimens
5 Results and Discussion
5.1 Nozzle-Based Multi-material Deposition
5.2 Electrophotographic Powder Pattern Development
5.3 Consolidation of Multi-material Powder Layers Prepared by Vibrating Nozzles
5.4 Dynamic Mechanical Properties of Resin Infused Polymer Powder Specimens
6 Conclusion
References
Extreme High-Speed Laser Material Deposition (EHLA) as High-Potential Coating Method for Tribological Contacts in Hydraulic Applications
1 Introduction
1.1 Motivation
1.2 Objective
2 Materials and Methods
2.1 Extreme High-Speed Material Deposition (EHLA)
2.2 Coating Material
2.3 Surface Finish
2.4 Tribological Approach and Parameters
3 Results
3.1 Coating Process
3.2 Wear
3.3 Stribeck Curves
4 Discussion
5 Conclusion and Outlook
References
In-Situ Alloying in Gas Metal Arc Welding for Wire and Arc Additive Manufacturing
1 Introduction
2 Experimental Setup
3 Experiments
4 Results and Discussion
4.1 Chemical Composition
4.2 Morphology
5 Summary
References
Casting
Development of an In-Situ Observation Procedure for Hot Tear Formation in Aluminum Alloys in Gravity Die Casting
1 Introduction
2 Development of Experimental Setup
3 Experiments
4 Results
4.1 In-Situ Observation
4.2 Chemical Composition
4.3 Morphology
5 Conclusions
References
Determination of the Heat Transfer Coefficient for a Liquid-Solid Contact in Gravity Die Casting Processes
1 Introduction
2 Topographical Analysis
2.1 Surface Profile Model 1
2.2 Surface Profile Model 2
2.3 Surface Profile Model 3
2.4 Surface Profile Model 4
3 Mechanical Analysis
3.1 Wetting Model A
3.2 Wetting Model B
3.3 Wetting Model C
3.4 Wetting Model D
3.5 Wetting Model E
4 Comparison of Wetting and HTC Predictions
5 Conclusion
References
Micro-macro Coupled Solidification Simulations of a Sr-Modified Al-Si-Mg Alloy in Permanent Mould Casting
1 Introduction
2 The Casting Experiments
3 Macroscopic Casting Simulation Model
3.1 The FE Simulation Model
4 Microstructure Simulation
4.1 Effect of Sr-Modification on the Eutectic Solidification
4.2 Impact of Cooling Rates on Solidification Path
5 Results of Micro-macro Coupled Simulation
6 Conclusions and Outlooks
References
Molding
Analysis of Radial Heat Transfer in an Injection Mold with Highly Dynamic Segmented Mold Tempering
1 Introduction
2 Injection Mold with High Segmented Temperature Control
3 Model Predictive Control Approach
3.1 Prediction and Control Mechanism
3.2 Simulation and Modelling of Radial Heat Transfer
4 Heating Trials to Quantify the Impact of Radial Heat Transfer
4.1 Calibration of the Ceramic Heating Elements
4.2 Analyzing the Impact of Radial Heat Transfer
5 Conclusion and Outlook
References
Evaluation and Transport of the Crystallization Heat in an Iterative Self-consistent Multi-scale Simulation of Semi-crystalline Thermoplastics
1 Introduction
2 The Self-consistent Approach Within the Multiscale Simulation Chain
2.1 Self-consistency of the Multiscale Simulation Scheme
2.2 Macroscale Filling Simulation
2.3 Microscale Superstructure Simulation (SphaeroSim)
3 Implementation of the Thermal Transport in the Microstructure Simulation
4 Crystallization Heat in SphaeroSim
4.1 Implemented Crystallization Kinetics Model
4.2 Comparison of the Calculation of Crystallization Heat at micro- and Macroscale
5 Conclusion and Outlook
References
Thermal Optimisation of Injection Moulds by Solving an Inverse Heat Conduction Problem
1 Introduction
2 State of the Art on Automatic Cooling Channel Generation
3 Thermal Optimization – Revising the Objective Function
4 Experimental - Thermal Optimisations
5 Results and Discussion
6 Conclusion and Outlook
References
Reduction of Internal Stresses in Optics Through a Demand-Oriented Cooling Channel Layout in Injection Moulding
1 Introduction
2 Inverse Thermal Cooling Channel Design
2.1 Calculation of an Inverse Demand-Oriented Cooling Channel Design
3 Investigation of a Demand-Oriented Cooling Channel Layout for Thick-Walled Optics in Injection Moulding
3.1 Geometry of the Plastic Lens
3.2 Adaption of the Methodology
3.3 Designing of Demand-Oriented Cooling Channels
3.4 Implementation of the Injection Moulding Simulations
3.5 Analysis of the Simulation Results with Special Regard to the Optical Properties
4 Conclusion and Outlook
References
Inverse Design Method for Injection Molding Cavity Shapes
1 Introduction
2 Injection Molding Simulation
3 Inverse Elasticity Formulation
4 Numerical Example
5 Iteration Method
6 Conclusion
References
Cutting
Cutting Whistle – An Original Approach for Nozzle Design in Fiber Laser Cutting of Stainless Steel
1 Introduction
2 Fundamentals of Whistling Mechanisms
3 Experimental Setup
3.1 Acoustic Sensing Experiments
3.2 Cutting Experiments
4 Results and Discussion
5 Conclusion and Further Outlook
References
Optimization of Beam Shapes for Laser Fusion Cutting by 3D Simulation of Melt Flow
1 Introduction
2 Related Work
3 Methodology
3.1 Simulation of Laser Fusion Cutting
3.2 Extraction of Quality Features
3.3 Beam Shape
4 Findings
4.1 Variation of Beam Shape for Fiber Lasers
4.2 Comparison of CO2 and Fiber Lasers for Gaussian and Top-Hat Beams
5 Conclusion
5.1 Limitations
References
Author Index