Unlike conventional materials removal methods, additive manufacturing (AM) is based on a novel materials incremental manufacturing philosophy. Additive manufacturing implies layer by layer shaping and consolidation of powder feedstock to arbitrary configurations, normally using a computer controlled laser. The current development focus of AM is to produce complex shaped functional metallic components, including metals, alloys and metal matrix composites (MMCs), to meet demanding requirements from aerospace, defence, automotive and biomedical industries. Laser sintering (LS), laser melting (LM) and laser metal deposition (LMD) are presently regarded as the three most versatile AM processes. Laser based AM processes generally have a complex non-equilibrium physical and chemical metallurgical nature, which is material and process dependent. The influence of material characteristics and processing conditions on metallurgical mechanisms and resultant microstructural and mechanical properties of AM proc...

Laser additive manufacturing of metallic components: materials, processes and mechanisms

An algebraic method that includes Gibbs minimization for performing phase equilibrium calculations for any number of components or phases

We present and discuss a framework for computer-aided multiscale analysis, which enables models at a fine (microscopic/stochastic) level of description to perform modeling tasks at a coarse (macroscopic, systems) level. These macroscopic modeling tasks, yielding information over long time and large space scales, are accomplished through appropriately initialized calls to the microscopic simulator for only short times and small spatial domains. Traditional modeling approaches first involve the derivation of macroscopic evolution equations (balances closed through constitutive relations). An arsenal of analytical and numerical techniques for the efficient solution of such evolution equations (usually Partial Differential Equations, PDEs) is then brought to bear on the problem. Our equation-free (EF) approach, introduced in (1), when successful, can bypass the derivation of the macroscopic evolution equations when these equations conceptually exist but are not available in closed form. We discuss how the mathematics-assisted development of a computational superstructure may enable alternative descriptions of the problem physics (e.g. Lattice Boltzmann (LB), kinetic Monte Carlo (KMC) or Molecular Dynamics (MD) microscopic simulators, executed over relatively short time and space scales) to perform systems level tasks (integration over relatively large time and space scales,"coarse" bifurcation analysis, optimization, and control) directly. In effect, the procedure constitutes a system identification based, "closure-on-demand" computational toolkit, bridging microscopic/stochastic simulation with traditional continuum scientific computation and numerical analysis. We will briefly survey the application of these "numerical enabling technology" ideas through examples including the computation of coarsely self-similar solutions, and discuss various features, limitations and potential extensions of the approach.

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Equation-Free, Coarse-Grained Multiscale Computation: Enabling Mocroscopic Simulators to Perform System-Level Analysis

CO2-H2O mixtures in the geological sequestration of CO2. I. Assessment and calculation of mutual solubilities from 12 to 100°C and up to 600 bar

Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on thermoelectric energy between the work piece and an electrode. A pulse discharge occurs in a small gap between the work piece and the electrode and removes the unwanted material from the parent metal through melting and vaporising. The electrode and the work piece must have electrical conductivity in order to generate the spark. There are various types of products which can be produced using EDM such as dies and moulds. Parts of aerospace, automotive industry and surgical components can be finished by EDM. This paper reviews the research trends in EDM on ultrasonic vibration, dry EDM machining, EDM with powder additives, EDM in water and modeling technique in predicting EDM performances.

A review on current research trends in electrical discharge machining (EDM)

A simple cathode erosion model for the electrical discharge machining (EDM) process is presented. This point heat‐source model differs from previous conduction models in that it accepts power rather than temperature as the boundary condition at the plasma/cathode interface. Optimum pulse times are predicted to within an average of 16% over a two‐decade range after the model is tuned to a single experimental point. A constant fraction of the total power supplied to the gap is transferred to the cathode over a wide range of currents. A universal, dimensionless model is then presented which identifies the key parameters of optimum pulse time factor (g) and erodibility (j) in terms of the thermophysical properties of the cathode material. Compton’s original energy balance for gas discharges is amended for EDM conditions. Here it is believed that the high density of the liquid dielectric causes plasmas of higher energy intensity and pressure than those for gas discharges. These differences of macroscopic diele...

Theoretical models of the electrical discharge machining process. I. A simple cathode erosion model

As a second in a series of theoretical models for the electrical discharge machining (EDM) process, an erosion model for the anode material is presented As with our point heat‐source model in the previous article, the present model also accepts power rather than temperature as the boundary condition at the plasma/anode interface A constant fraction of the total power supplied to the gap is transferred to the anode The power supplied is assumed to produce a Gaussian‐distributed heat flux on the surface of the anode material Furthermore, the area upon which the flux is incident is assumed to grow with time The model is capable of showing, via the determined migrating melt fronts, the rapid melting of the anodic material as well as the subsequent resolidification of the material foation from plasma dynamics modeling could improve substantially our results

Theoretical models of the electrical discharge machining process. II. The anode erosion model

A variable mass, cylindrical plasma model (VMCPM) is developed for sparks created by electrical discharge in a liquid media. The model consist of three differential equations—one each from fluid dynamics, an energy balance, and the radiation equation—combined with a plasma equation of state. A thermophysical property subroutine allows realistic estimation of plasma enthalpy, mass density, and particle fractions by inclusion of the heats of dissociation and ionization for a plasma created from deionized water. Problems with the zero‐time boundary conditions are overcome by an electron balance procedure. Numerical solution of the model provides plasma radius, temperature, pressure, and mass as a function of pulse time for fixed current, electrode gap, and power fraction remaining in the plasma. Moderately high temperatures (≳5000 K) and pressures (≳4 bar) persist in the sparks even after long pulse times (to ∼500 μs). Quantitative proof that superheating is the dominant mechanism for electrical discharge ma...

Theoretical models of the electrical discharge machining process. III. The variable mass, cylindrical plasma model

A process for converting natural gas to a liquid includes heating the gas to a selected range of temperature to convert a fraction of the gas stream to reactive hydrocarbons, primarily ethylene or acetylene, and reacting methane and the reactive hydrocarbons in the presence of an acidic catalyst to produce a liquid, predominantly naphtha or gasoline. A portion of the incoming natural gas may be used to heat the remainder of the natural gas to the selected range of temperature. Hydrogen resulting from the reactions may be used to make electricity in a fuel cell. Alternatively, hydrogen may be burned to heat the natural gas to the selected range of temperature.

Philip T. Eubank

Papers

An algebraic method that includes Gibbs minimization for performing phase equilibrium calculations for any number of components or phases

Theoretical models of the electrical discharge machining process. I. A simple cathode erosion model

Theoretical models of the electrical discharge machining process. II. The anode erosion model

Theoretical models of the electrical discharge machining process. III. The variable mass, cylindrical plasma model

Method for converting natural gas to liquid hydrocarbons