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A novel computational supplement to an IR-thermography based non-destructive test of electrofusion polyethylene joints
摘要： Electrofusion Polyethylene (PE) joints are important elements of the gas distribution networks. Unfortunately they are prone to leakage if not tested thoroughly. Our team has recently proposed a novel noncontact and IR thermal non-destructive test for these PE joints. That is, to induce a controlled heat pulse within the joint via its internal wire, and compare its thermal response with other experimental reference cases. Two gaps exist in this method due to the lack of access to a mathematical model. Firstly the pulsing duration at different initial temperatures are only determined by trial and errors. Secondly, preparing experimental reference thermal images at different joint conditions is considerably costly. Therefore, here we rigorously simulate this pulsing process to tackle both abovementioned shortcomings. We experimentally validate our simulation and report the appropriate pulsing durations between 300 K and 320 K initial temperatures. Moreover, we successfully screen a contaminated joint nondestructively.
关键词： Non destructive testing,Dynamic heat transfer,Non-contact IR test,Electrofusion polyethylene joint,IR thermal imaging
更新于2025-09-23 15:21:01
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Multi-physics modelling of molten pool development and track formation in multi-track, multi-layer and multi-material selective laser melting
摘要： Selective laser melting (SLM) is a promising powder-based additive manufacturing technology due to its capability to fabricate metallic components with complex geometries. While most previous investigations focus on printing with a single material, recent industry-orientated studies indicate the need for multi-material SLM in several high-value manufacturing sectors including medical devices, aerospace and automotive industries. However, understanding the underlying physics in multi-material SLM remains challenging due to the di?culties of experimental observation. In this paper, an integrated modelling framework for multi-track, multi-layer and multi-material SLM is developed to advance the in-depth understanding of this process. The main novelty is in modelling the molten pool evolvement and track morphology of multiple materials deposited on the same and across different layers. Discrete element method (DEM) is employed to reproduce the powder deposition process of multiple materials in different deposition patterns, with particle size distribution imported from a particle size analyser. Various phenomena including balling effect, keyhole depression, and lack of fusion between layers are investigated with different laser energy inputs. As a result of the different thermal properties, several process parameters including energy density and hatch spacing are optimised for different powder materials to obtain a continuous track pro?le and improved scanning e?ciency. The interface between two layers of different materials is visualised by simulation; it was found that the phase migration at the interface is related to the convection ?ow inside the molten pool, which contributes to the mixing of the two materials and elemental diffusion. This study signi?cantly contributes to the challenging area of multi-material additive manufacturing by providing a greater in-depth understanding of the SLM process from multi-material powder deposition to laser interaction with powders across multiple scanning tracks and different building layers than can be achieved by experimentation alone.
关键词： Additive manufacturing,Discrete element method (DEM),Computational ?uid dynamics (CFD),Heat transfer,Multi-material,Selective laser melting (SLM)
更新于2025-09-23 15:19:57
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Evaluation of performance of near-field thermophotovoltaic systems based on entropy analysis
摘要： Near-field radiative heat transfer can significantly improve the output power of thermophotovoltaic (TPV) systems. Therefore, it is crucial to explore how to increase the energy conversion efficiencies of near-field TPV systems. In this study, based on the fluctuation–dissipation theorem with the effective medium theory, we evaluate the performance of a near-field TPV system from the formulation of thermodynamics. It is found that a near-field TPV system consisting of InAs or GaSb cell can achieve higher heat flux or efficiency limit, respectively. Moreover, the TPV system with a hyperbolic metamaterial (HMM) emitter composed of nanowire or nanohole arrays can achieve higher heat flux and efficiency limit compared to that of the bulk reference. This is attributable to the HMMs being able to support hyperbolic modes, and the radiation with the HMM emitter exhibits a favorable entropy content for the energy conversion efficiency. This work provides an approach to determine the efficiency limit and establish a target for efficiency of the near-field TPV system without considering how the system works. The results of this study will facilitate the design and application of the HMM emitter and material of the TPV cell to improve the efficiency of near-field TPV systems.
关键词： Thermophotovoltaic systems,Near-field radiative heat transfer,Energy conversion efficiency,Hyperbolic metamaterial,Entropy analysis
更新于2025-09-23 15:19:57
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Performance enhancement of photovoltaic panels using two types of nanofluids
摘要： One of the main problems that limit the extensive use of photovoltaic (PV) systems is the increase in the temperature of PV panels. Overheating of a PV module decreases the performance of the output power by 0.4% to 0.5% per 1°C over its rated temperature that in most cases is 25°C. An effective way of improving electrical performance (power output and efficiency) and reducing the rate of thermal degradation of a PV module is to reduce the operating temperature of the PV surface by a cooling medium. To achieve this, nanofluids can be considered as a potentially effective solution for cooling. In this study, two types of nanofluids, namely Al2O3 and TiO2 water‐based mixture of different volume flow rates and concentrations (0.01%, 0.05%, and 0.1%) by weight, were used. Also, three PV panels were cooled simultaneously using nanofluids, water, and natural air, respectively. Results showed that nanofluids for cooling enhanced heat transfer rate much better than water and natural air. Best results were achieved for TiO2 nanofluids at the considered concentration (0.1 wt%). Nanofluid cooling of turbulent flows for such an application has not been investigated before. These results represent the first application of nanofluid cooling in the turbulent flow regimes and in outdoor conditions including real solar irradiation.
关键词： photovoltaic module,Nusselt number,Al2O3,TiO2 nanofluids,heat transfer,electrical performance
更新于2025-09-23 15:19:57
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New Method for Studying the Ignition Characteristics of Condensed Systems by Laser Radiation
摘要： A method for determining the characteristics of laser ignition of the condensed systems is presented, which ensures uniform distribution of the heat flux density over the surface during ignition. The method consists in measuring the ignition delay time of a rotating cylindrical sample when the continuous laser heat flux is applied to its end surface. The theoretical estimation of the required angular rotation velocity of the sample is carried out, which ensures averaging with a given error of the radiation flux density on the surface of the sample, as well as the degree of surface cooling due to the convective heat transfer. The experimental results on the pyroxylin sample ignition at the radiant heating by a CO2 laser with and without rotation of the sample are presented.
关键词： pyroxylin,laser ignition,ignition delay time,condensed system,convective heat transfer,angular velocity of rotation
更新于2025-09-23 15:19:57
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Studies on the formation mechanism of incomplete fusion defects in ultra-narrow gap laser wire filling welding
摘要： Austenitic stainless steel has many excellent properties and it has been extensively used in rail transit trains. Ultra-narrow gap laser wire filling welding is the preferred welding method to connect austenitic stainless steel. However, with this method, it is easy to form defects such as lack of fusion in the welding process. In order to clarify the mechanism of incomplete fusion defects, this article analyzed incomplete fusion defects from the groove design and the welding wire transfer behavior, integrating with high-speed photography and finite element simulation. It is found that the form of narrow gap groove has a close relationship with the formation of fusible defects. Besides, under the condition of globular transfer, all the complicated recoil force, blocking effect of the large droplet on laser energy, the eruption of metal vapor and turbulence of the molten pool caused by large droplet transfer will cause violent disturbance of the molten pool and seriously affect its heat conduction effect. The base metal incompletely melting, the lack of transfer driving force on the droplet and the failure of droplet wetting and spreading on the sidewalls of the groove are the main causes of welding non-fusion defects. Designing reasonable groove, ensuring the stability of wire feeding, adopting liquid bridge transfer mode and appropriately increasing heat input are conducive to reduce the occurrence of incomplete fusion, which is essential to improve the welding quality and enhance the safety of rail vehicles.
关键词： Ultra-narrow gap,Numerical simulation,The heat transfer mechanism,Incomplete fusion
更新于2025-09-23 15:19:57
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Near-Field Radiative Heat Transfer between Dissimilar Materials Mediated by Coupled Surface Phonon- and Plasmon-Polaritons
摘要： Near-field radiative heat transfer (NFRHT) between dissimilar materials supporting surface polaritons in the infrared is of critical importance for applications such as photonic thermal rectification and near-field thermophotovoltaics. Here, we measure NFRHT between millimeter-size surfaces made of 6H-SiC and doped Si, respectively supporting surface phonon-polaritons (SPhPs) and surface plasmon-polaritons (SPPs) in the infrared, separated by a 150-nm-thick vacuum gap spacing maintained via SiO2 nanopillars. For purpose of comparison, measurements are also performed between two doped Si surfaces. The measured radiative flux is in good agreement with theoretical predictions based on fluctuational electrodynamics. A flux enhancement beyond the blackbody limit of ~ 8.2 is obtained for the SiC-Si sample, which is smaller than the enhancement for the Si-Si sample (~ 12.5) owing to the spectral mismatch of the SiC and Si light lines, and SPhP and SPP resonances. However, due to lower losses in SiC than Si and weaker SPhP-SPP coupling than SPP coupling, the near-field enhancement for the SiC-Si sample exhibits a more pronounced monochromatic behavior with a resonant flux that is ~ 5 times larger than the resonant flux for the Si-Si sample. This work demonstrates that it is possible to modulate NFRHT via surface polariton coupling, and will accelerate the development of energy conversion and thermal management devices capitalizing on the near-field effects of thermal radiation between dissimilar materials.
关键词： radiative flux measurement,doped silicon,near-field radiative heat transfer,dissimilar materials,coupled surface phonon- and plasmon-polaritons,silicon carbide
更新于2025-09-23 15:19:57
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Sequences of Sub-Microsecond Laser Pulses for Material Processing: Modeling of Coupled Gas Dynamics and Heat Transfer
摘要： Multipulse laser processing of materials is promising because of the additional possibilities to control the thickness of the treated and the heat-affected zones and the energy efficiency. To study the physics of mutual interaction of pulses at high repetition rate, a model is proposed where heat transfer in the target and gas-dynamics of vapor and ambient gas are coupled by the gas-dynamic boundary conditions of evaporation/condensation. Numerical calculations are accomplished for a substrate of an austenitic steel subjected to a 300 ns single pulse of CO2 laser and a sequence of the similar pulses with lower intensity and 10 μs inter-pulse separation assuring approximately the same thermal impact on the target. It is revealed that the pulses of the sequence interact due to heat accumulation in the target but they cannot interact through the gas phase. Evaporation is considerably more intensive at the single-pulse processing. The vapor is slightly ionized and absorbs the infrared laser radiation by inverse bremsstrahlung. The estimated absorption coefficient and the optical thickness of the vapor domain are considerably greater for the single-pulse regime. The absorption initiates optical breakdown and the ignition of plasma shielding the target from laser radiation. The multipulse laser processing can be applied to avoid plasma ignition.
关键词： laser evaporation,multipulse laser processing,laser plasma,heat transfer,gas dynamics
更新于2025-09-23 15:19:57
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Recent Problems of Heat-Transfer Simulation in Technological Processes of Selective Laser Melting and Fusion
摘要： The thermal processes arising upon the implementation of the additive technologies of selective laser melting and the fusion of metals and alloys are analyzed. An adequate description of the heat transfer upon the implementation of additive technological processes associated with high-intensity local heating by a moving laser beam and the phase transitions generated by a semifinished powder product, crystallization, and the concomitant effects in the growing element is the key to gaining insight into the microstructure and the efficient properties of the obtained material and the prevention of residual deformation (shrinkage) of the item. Currently, the main causes of unpredictable production defects are deviations of the shape of the final item from the preset geometry and high-amplitude residual stresses, which can initiate destruction of the item under loads significantly lower than those calculated, as well as the occurrence of the microscopic defects (pores, layer interfaces, etc.) are. The development of mathematical models that, on the one hand, are sufficiently accurate to predict the listed phenomena and, on the other hand, allow practical implementation in engineering calculations is the basis for the further development of the laser-melting and fusion of metal materials. At the same time, analysis of the current state of the problem shows that development of efficient numerical methods providing acceptable computational costs while maintaining accuracy is the key element in the practical implementation of the models. A method based on multiscale, interconnected modeling of the mechanical and the thermal state of the growing body—at the local level in the melt pool domain, at the intermediate level in the vicinity of the melt pool and the adjacent layers, and at the level of the entire product as a whole—seems to be efficient; here, the computing process at the global level can be based on a combination of the finite-element method (indisputable in practice) and analytical calculations providing local refinement of the solution.
关键词： numerical methods,heat-transfer simulation,microstructure,residual deformation,mathematical models,fusion,thermal processes,selective laser melting,additive technologies
更新于2025-09-23 15:19:57
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Size- and Surface-Dependent Photoresponses of Solution-Processed Aluminum Nanoparticles
摘要： Plasmonic aluminum nanoparticles have emerged as an exciting new materials platform due to the high natural abundance of aluminum, their ability to be synthesized in the solution phase, and the potential of these materials to be used for photocatalysis and sensing. However, the photothermal properties of solution-processed aluminum nanoparticles, in particular, how phonon energy transfer depends on the particle size and surface properties, are critical for practical applications and are currently unexplored. Here we use transient absorption spectroscopy, in combination with simulations of phonon and thermal energy dissipation, to investigate the photoresponses of aluminum nanoparticles of various diameters (54, 85, 121, and 144 nm) suspended in 2-propanol. Fast thermal-transfer rates to the solvent (170?280 ps) are observed for particles of all sizes and are facilitated by native oxide coverage, as veri?ed by a two-interface thermal energy-transfer model. Size-dependent phonon “breathing”/vibrational modes are also observed as oscillations in the total cross-section. We ?nd that both the oscillation frequency and the damping rate increase as the diameter of the particles decreases. On the basis of the results of ?nite element calculations, we attribute the damping strength and oscillation period observed to a combination of the noncrystalline nature of the native oxide shell and the presence of surface-bound ligands, both of which increase the vibrational mode damping rates relative to bare Al and Al particles with a bare crystalline oxide shell. These insights should guide future work on controlling energy transfer through the use of size and surface tuning in sustainable aluminum nanomaterial systems for applications in catalysis and sensing.
关键词： aluminum,phonons,surface effects,transient absorption,heat transfer,localized surface plasmon resonances
更新于2025-09-23 15:19:57