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Principles Of Enhanced Heat Transfer

Additive Manufacturing (AM) is the significantly progressing field in terms of methods, materials, and performance of fabricated parts. Periodical evaluation on the understanding of AM processes and its evolution is needed since the field is growing rapidly. To address this requirement, this paper presents a detailed review of the Additive Manufacturing (AM) methods, materials used, and challenges associated with them. A critical review of the state of art materials in the categories such as metals and alloys, polymers, ceramics, and biomaterials are presented along with their applications, benefits, and the problems associated with the formation of microstructures, mechanical properties, and controlling process parameters. The perspectives and the status of different materials on the fabrication of thin-walled structures using AM techniques have also been discussed. Additionally, the main challenges with AM techniques such as inaccuracy, surface quality, reinforcement distribution, and other common problems identified from the literature are presented. On the whole, this paper provides a comprehensive outlook on AM techniques, challenges, and future research directions.

Methods and materials for additive manufacturing: A critical review on advancements and challenges

Dynamic heat exchanger model for performance prediction and control system design of automotive waste heat recovery systems

Abstract Metal additive manufacturing (AM) encapsulates the myriad of manufacturing processes available to meet industrial needs. Determining which of these AM processes is best for a specific aerospace application can be overwhelming. Based on the application, each of these AM processes has advantages and challenges. The most common metal AM methods in use include Powder Bed Fusion, Directed Energy Deposition, and various solid-state processes. Within each of these processes, there are different energy sources and feedstock requirements. Component requirements heavily affect the process determination, despite existing literature on these AM processes (often inclusive of input parameters and material properties). This article provides an overview of the considerations taken for metal AM process selection for aerospace components based on various attributes. These attributes include geometric considerations, metallurgical characteristics and properties, cost basis, post-processing, and industrialization supply chain maturity. To provide information for trade studies and selection, data on these attributes were compiled through literature reviews, internal NASA studies, as well as academic and industry partner studies and data. These studies include multiple AM components and sample build experiments to evaluate (1) material and geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) qualification approaches. This article summarizes these results and is meant to introduce various considerations when designing a metal AM component. 

https://link.springer.com/content/pdf/10.1007/s11665-022-06850-0.pdf

Robust Metal Additive Manufacturing Process Selection and Development for Aerospace Components

Additive manufacturing (AM) has gained extensive attention and tremendous research due to its advantages of fabricating complex-shaped parts without the need of casting mold. However, distortion is a known issue for many AM technologies, which decreases the precision of as-built parts. Like fusion welding, the local high-energy input generates residual stresses, which can adversely affect the fatigue performance of AM parts. To the best of the authors’ knowledge, a comprehensive review does not exist regarding the distortion and residual stresses dedicated for AM, despite some work has explored the interrelationship between the two. The present review is aimed to fill in the identified knowledge gap, by first describing the evolution of distortion and residual stresses for a range of AM processes, and second assessing their influencing factors. This allows us to elucidate their formation mechanisms from both the micro- and macro-scales. Moreover, approaches which have been successfully adopted to mitigate both the distortion and residual stresses are reviewed. It is anticipated that this review paper opens many opportunities to increase the success rate of AM parts by improving the dimension precision and fatigue life. 

A Review on Distortion and Residual Stress in Additive Manufacturing

EHD-based load controllers for R134a convective boiling heat exchangers

Phenomenological correlations for two phase heat transfer and pressure drop performance of electrohydrodynamic horizontal convective boiling of dielectric fluids

iv ACKOWLEDGEMENT vi LIST OF FIGURES ix LIST OF TABLES xiii NOMENCLATURE xiv Chapter 1: Introduction 1 1.1 Heat Exchanger Technology and Convective Boiling Enhancement Techniques 1 1.2 Control Techniques 8 1.3 Research Objective 10 Chapter 1: Electrohydrodynamics and Heat Transfer 11 2.

https://macsphere.mcmaster.ca/bitstream/11375/12460/1/fulltext.pdf

The Effect of High Voltage Electric Fields on Two Phase Flow Pattern Redistribution and Heat Exchanger Performance

A mechanistic approach to developing two phase flow pattern transition maps for two-phase dielectric fluids subject to high voltage polarization

Residual stresses are induced during selective laser melting (SLM) because of rapid melting, solidification and build plate removal. This paper aims to examine the thermal cycle, residual stresses and part distortions for selected aerospace materials (i.e. Ti-6Al-4V, stainless steel 316L and Invar 36) using a thermo-mechanical finite element model. The numerical results are validated and compared to experimental data.,The model predicts the residual stress and part distortion after build plate removal. The residual stress field is validated using X-ray diffraction method and the part distortion is validated using dimensional measurements.,The trends found in the numerical results agree with those found experimentally. Invar 36 had the lowest tensile residual stresses because of its lowest coefficient of thermal expansion. The residual stresses of stainless steel 316L were lower than those of Ti-6Al-4V because of its high thermal diffusivity.,The model predicts residual stresses at the optimal SLM process parameters. However, using any other process conditions could cause void formation and/or alloying element vaporization, which would require the inclusion of melt pool physics in the model.,The paper explains the influence of the coefficient of thermal expansion and thermal diffusivity on the induced thermal stresses using experimental and numerical results. The methodology can be used to predict the part distortions and residual stresses in complex designs of any of the three materials under optimal SLM process parameters.

Influence of thermal properties on residual stresses in SLM of aerospace alloys

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