Molten droplet solidification and substrate remelting in microcasting Part I: numerical modeling and experimental verification

This paper presents a numerical model of a molten metal droplet impinging, solidifying and bonding to a solid substrate. The physical and numerical model includes dissimilar materials, multi-dimensional axisymmetric heat transfer, tracking of solid/liquid interfaces during remelting and solidification, and coupled treatment of the continuous droplet/substrate region. The numerical model solves for the evolution of the temperature distribution in the droplet and substrate, predicts the position of the remelting and solidification fronts, and accounts for convective motion. The effect of the convection induced by the droplet spreading is modeled through a time-dependent effective thermal conductivity. High-speed filming of the molten droplet impinging and spreading on the substrate is performed to obtain the required parameters to determine this time dependent effective conductivity. The accuracy of the model is investigated with experimental techniques. This research is directly related to the development of microcasting Shape Deposition Manufacturing (SDM) which is a process for automatically fabricating complex multi-material objects by sequentially depositing material layers. Microcasting is a molten metal droplet deposition process in SDM, which is able to create fully dense metal layers with controlled microstructure. Important issues in the production of high quality objects manufactured with microcasting SDM are: attainment of interlayer metallurgical bonding through substrate remelting, control of both substrate and droplet cooling rates, and minimization of residual thermal stresses. To validate experimentally the numerical modeling approach, predicted cooling rates are compared with thermocouple measurements and substrate remelting depths are verified through optical metallographic techniques. Received on 10 June 1998     

Multi-scale defect interactions in high-rate failure of brittle materials,Part II: Application to design of protection materials

Micromechanics based damage models, such as the model presented in Part I of this 2 part series (Tonge and Ramesh, 2015), have the potential to suggest promising directions for materials design. However, to reach their full potential these models must demonstrate that they capture the relevant physical processes. In this work, we apply the multiscale material model described in Tonge and Ramesh (2015) to ballistic impacts on the advanced ceramic boron carbide and suggest possible directions for improving the performance of boron carbide under impact conditions. We simulate both dynamic uniaxial compression and simplified ballistic loading geometries to demonstrate that the material model captures the relevant physics in these problems and to interrogate the sensitivity of the simulation results to some of the model input parameters. Under dynamic compression, we show that the simulated peak strength is sensitive to the maximum crack growth velocity and the flaw distribution, while the stress collapse portion of the test is partially influenced by the granular flow behavior of the fully damaged material. From simulations of simplified ballistic impact, we suggest that the total amount of granular flow (a possible performance metric) can be reduced by either a larger granular flow slope (more angular fragments) or a larger granular flow timescale (larger fragments). We then discuss the implications for materials design.     

The computation of stress intensity factors in dissimilar materials

A reciprocal work contour integral method for calculating stress intensity factors is extended to treat the problem of two bonded dissimilar materials containing a crack along the bond. The method is based on Betti's Reciprocal work theorem from which the singular stress intensities at the crack tip may be evaluated in terms of an integral involving tractions and displacements on a contour remote from the crack tip.     

Parametric vibrations of flexible hoses excited by a pulsating fluid flow,Part II: Experimental research

The paper presents the results of experimental studies of vibrations of an elastic hose which are induced by a pulsating fluid flow. It was found that there is a possibility of parametric resonances: principal and combination associated with certain modes of vibrations. The influence of frequency and the amplitude of pulsation, average flow velocity, pressure inside pipe, the length of the hose, and the temperature on the ranges of parametric vibrations were analysed. The character of vibrations in resonance ranges was determined by showing time histories and the results of spectral analyses. A flexible hose applied in high-pressure hydraulic systems was used as an object of research. The values of basic parameters which describe the hose׳s mechanical properties were identified experimentally. The results of the experiments were compared with the results of numerical simulations conducted on the basis of the methodology proposed in Part I of this paper.     

A semi-infinite interface crack interacting with subinterface matrix cracks in dissimilar anisotropic materials. II. Numerical results and discussion

Based on the investigation performed in Part I of this series, numerical results for the interaction between a semi-infinite interface crack and multiple subinterface matrix microcracks in three kinds of material combinations are given in Part II. The major interaction behaviors are discussed in detail. Special attention is focused on the influences of the different material combinations, the T-stress, the orientation angles, and the location angles of the microcracks on the local stress intensity factor at the interface crack tip. In addition, the variable tendencies of the interaction effect induced from change of the distance between the interface crack tip and the centers of the microcracks are studied. It is concluded that the different material combinations introduced in this paper have little influence on the variable tendencies of the effect, but have significant influence on the effect in magnitude. Detailed comparisons of the results with those in a homogeneous orthotropic material show that the dissimilar materials shift the maximum amplification angle, the maximum shielding angle, the neutral shielding angle, and the neutral T-stress angle, respectively.     

Numerical and experimental study of the traveling magnetic field effect on the horizontal solidification in a rectangular cavity part 2: Acting forces ratio and solidification parameters

In recent decades, many phase change processes in metals have been optimized using traveling magnetic fields due to a better understanding of their electromagnetic impact in such applications. In this paper, numerical and experimental study of the effect of traveling magnetic field on the solidification process was evaluated. A three-dimensional numerical model based on the multi-domain method was used to analyze the process of gallium horizontal solidification under the electromagnetic impact in a laboratory-size rectangular cavity. A linear inductor creating traveling magnetic field was designed and built for appropriate measurements and validation the calculations. The analysis was focused on the influence of the ratio between the applied electromagnetic forces and natural convective forces on the solidification front location and shape and on the velocity field. Since the overall electromagnetic force impact on the melt reduced during the solidification, when the melt area was converting into a solid, a new approach to control the solidification parameters was analyzed. In this approach, the value of electromagnetic force acting on the remaining melt during the process was maintained. The main result is the development and improvement of an effective tool for the analysis of direct solidification parameters.The experimental setup included an ultrasonic Doppler velocimeter (UDV) for noninvasive measurements of the velocities in the liquid part of the metal and the liquid-solid interface position, its profile and displacement. All important characteristics of the process were measured, and the results of computations agreed well enough with experimentally obtained data.     

Elongated bubbles in microchannels. Part II: Experimental study and modeling of bubble collisions

The collision of elongated bubbles has been studied along adiabatic glass microchannels of 509 and 790 μm internal diameters for refrigerant R-134a. The slug flow regime obtained here comes from the nucleation process inside a micro-evaporator located upstream. Using an optical measurement technique based on two lasers and two photodiodes, it was possible to determine the vapor bubble length distributions at the exit of the micro-evaporator and 70 mm downstream and thus characterize both diabatic and adiabatic bubble collisions. The database includes 412 coupled sets of distributions involving thousands of bubbles. Half of the database has been obtained under diabatic conditions and the second half under adiabatic conditions.     

Multiscale lattice Boltzmann-finite element modelling of chloride diffusivity in cementitious materials. Part II: Simulation results and validation

Chloride diffusivity in cementitious materials depends on the underlying microstructure and environmental conditions. The algorithms and implementation of the multiscale lattice Boltzmann-finite element scheme for prediction of chloride diffusivity in cementitious materials was described in detail in Part I (Zhang et al., 2013). Based on the obtained microstructures and the developed multiscale modelling scheme, chloride diffusivity in cementitious materials at the micro- and meso-scales, i.e. cement paste, mortar and concrete, are estimated and presented in Part II. The influences of w/c ratio, age, chloride binding, degree of water saturation, interfacial transition zone (ITZ) and aggregate content on chloride diffusivity are investigated in a quantitative manner. The simulations are validated with experimental data obtained from literature. The results indicate that the simulated chloride diffusivity in cementitious materials at each scale shows a good agreement with experimental data. In addition, the chloride binding, degree of water saturation, ITZ and aggregate content play significant roles in the chloride diffusivity in cementitious materials. The estimated chloride diffusivity in cementitious materials in this study accounting for the evolution of microstructure and environmental conditions can be directly used as input for the service life prediction of reinforced concrete structures.     

Stress channelling in extreme couple-stress materials Part II: Localized folding vs faulting of a continuum in single and cross geometries

The antiplane strain Green's functions for an applied concentrated force and moment are obtained for Cosserat elastic solids with extreme anisotropy, which can be tailored to bring the material in a state close to an instability threshold such as failure of ellipticity. It is shown that the wave propagation condition (and not ellipticity) governs the behaviour of the antiplane strain Green's functions. These Green's functions are used as perturbing agents to demonstrate in an extreme material the emergence of localized (single and cross) stress channelling and the emergence of antiplane localized folding (or creasing, or weak elastostatic shock) and faulting (or elastostatic shock) of a Cosserat continuum, phenomena which remain excluded for a Cauchy elastic material. During folding some components of the displacement gradient suffer a finite jump, whereas during faulting the displacement itself displays a finite discontinuity.     

Crack deflection at an interface between dissimilar elastic materials: Role of residual stresses

A crack intersecting an interface between two dissimilar materials may advance by either penetrating through the interface or deflecting into the interface. The competition between deflection and penetration can be assessed by comparison of two ratios: (i) the ratio of the energy release rates for interface cracking and crack penetration; and (ii) the ratio of interface to material fracture energies. Residual stresses caused by thermal expansion misfit can influence the energy release rates of both the deflected and penetrating crack. This paper analyses the role of residual stresses. The results reveal that expansion misfit can be profoundly important in systems with planar interfaces (such as layered materials, thin film structures, etc.), but generally can be expected to be of little significance in fiber composites. This paper corrects an earlier result for the ratio of the energy release rate for the doubly deflected crack to that for the penetrating crack in the absence of residual stress.     

Dynamic behaviors of droplet impact and spreading: A universal relationship study of dimensionless wetting diameter and droplet height

A notable universal relationship has been proposed in the literature for the evolution of dimensionless droplet height and wetting diameter during the initial spreading stage of droplet impingement. In this study, this universal relationship was investigated by employing three sets of measurements. Sequential images were recorded, and the whole droplet profile ensembles were plotted to facilitate this study. These sets of experiments were designed by changing impact velocity, surface hydrophobicity, or solution property. The experimental results illustrate that the importance of parameters causing the data variation is in the order of surface hydrophobicity > initial impact velocity > surfactant on wetting diameter, and surface hydrophobicity ≈ initial impact velocity > surfactant on droplet height. No universal relationship was observed for dimensionless droplet height and wetting diameter.     

A theory of strain-gradient plasticity for isotropic, plastically irrotational materials. Part II: Finite deformations

This paper generalizes to finite deformations our companion paper [Gurtin, M.E., Anand, L., 2004. A theory of strain-gradient plasticity for isotropic, plastically irrotational materials. Part I: Small deformations. Journal of the Mechanics and Physics of Solids, submitted]. Specifically, we develop a gradient theory for finite-deformation isotropic viscoplasticity in the absence of plastic spin. The theory is based on the Kröner–Lee decomposition F = F^eF^p of the deformation gradient into elastic and plastic parts; a system of microstresses consistent with a microforce balance; a mechanical version of the second law that includes, via microstresses, work performed during viscoplastic flow; a constitutive theory that allows:

• the microstresses to depend on D^p, the gradient of the plastic stretching,

• the free energy ψ to depend on the Burgers tensor G = F^pCurlF^p.

The microforce balance when augmented by constitutive relations for the microstresses results in a nonlocal flow rule in the form of a tensorial second-order partial differential equation for F^p. The microstresses are strictly dissipative when ψ is independent of the Burgers tensor, but when ψ depends on G the microstresses are partially energetic, and this, in turn, leads to backstresses and (hence) Bauschinger-effects in the flow rule. The typical macroscopic boundary conditions are supplemented by nonstandard microscopic boundary conditions associated with viscoplastic flow, and, as an aid to numerical solution, a weak (virtual power) formulation of the nonlocal flow rule is derived. Finally, the dependences of the microstresses on D^p are shown, analytically, to result in strengthening and possibly weakening of the body induced by viscoplastic flow.     

A coupled electromechanical analysis of a piezoelectric layer bonded to an elastic substrate: Part II,numerical solution and applications

This two-part contribution presents a novel and efficient method to analyze the two-dimensional (2-D) electromechanical fields of a piezoelectric layer bonded to an elastic substrate, which takes into account the fully coupled electric and mechanical behaviors. In Part I, we have obtained a system of governing integro-differential equations for the structure via a variational principle. This part presents a numerical solution algorithm of the integro-differential equations and the numerical results of some applications. A numerical algorithm for solving the system of four integro-differential equations with strongly singular kernels is developed. The convergence of the numerical algorithm is discussed. The numerical results suggest that the fully coupled electromechanical analysis is helpful for a better understanding of the performance of the piezoelectric sensor and actuator. The interfacial normal stress is much higher than the interfacial shear stress, suggesting that the interfacial normal stress causes a delamination initiation.     

Shear and elongational flow behavior of acrylic thickener solutions. Part II: effect of gel content

We have investigated the effect of crosslink density on shear and elongational flow properties of alkali-swellable acrylic thickener solutions using a mixing series of the two commercial thickeners Sterocoll FD and Sterocoll D as model system. Linear viscoelastic moduli show a smooth transition from weakly elastic to gel-like behavior. Steady shear data are very well described by a single mode Giesekus model at all mixing ratios. Extensional flow behavior has been characterized using the CaBER technique. Corresponding decay of filament diameter is also well fitted by the Giesekus model, except for the highest crosslink densities, when filament deformation is highly non-uniform, but the non-linearity parameter α, which is independent of the mixing ratio, is two orders of magnitude higher in shear compared to elongational flow. Shear relaxation times increase by orders of magnitude, but the characteristic elongational relaxation time decreases weakly, as gel content increases. Accordingly, variation of gel content is a valuable tool to adjust the low shear viscosity in a wide range while keeping extensional flow resistance essentially constant.     

Experimental study of thermoacoustic effects on a single plate Part II: Heat transfer

 Heat fluxes close to the edge of a heated solid plate aligned parallel to the axis of an acoustic standing wave were measured for drive ratios DR≡P _A/p _m of 1, 2 and 3. It was found that at the highest drive ratio (3), the resulting heat flux vector at the edge of the plate is directed into the plate, opposite to the direction of the heat flux imposed by the resistive heaters within the plate. This observation confirms the thermoacoustic effect previously detected in the visualized temperature fields and discussed in part I of this paper. Through the energy balance the magnitudes of the heat fluxes into the plate, caused by the thermoacoustic effect, were determined. The measured data are in good agreement with numerical and analytical predictions. Received on 18 August 1999     

Boundary film shear elastic modulus effect in hydrodynamic contact. Part II: influence of operational parameters

The present paper is the subsequent research of the first part (Theor Comput Fluid Dyn, 2009). It investigates the boundary film shear elastic modulus effect in a hydrodynamic contact in different operating conditions. The hydrodynamic contact is one-dimensional, composed of two parallel plane surfaces, which are respectively rough rigid with rectangular micro projections in profile periodically distributed on the surface and ideally smooth rigid. The whole contact consists of cavitated area and hydrodynamic area. The hydrodynamic area consists of many micro Raleigh bearings which are discontinuously and periodically distributed in the contact. The hydrodynamic contact in a micro Raleigh bearing consists of boundary film area and fluid film area which, respectively, occur in the outlet and inlet zones. In boundary film area, the film slips at the upper contact surface due to the limited shear stress capacity of the film–contact interface, while the film does not slip at the lower contact surface due to the shear stress capacity of the film–contact interface large enough. In boundary film area, the viscosity, density, and shear elastic modulus of the film are varied across the film thickness due to the film–contact interactions, and their effective values are used in modeling which depends on the film thickness. In fluid film area, the film does not slip at either of the contact surfaces, and the shear elastic modulus of the film is neglected. It is found from the simulation results that the boundary film shear elastic modulus influences are normally negligible on the mass flow through the contact, the carried load of the contact and the overall film thickness of the contact, and the boundary film shear elastic modulus would normally influence the local film thickness in an elastic contact when the local film thickness is on the film molecule diameter scale. It is also found that the boundary film shear elastic modulus effect has the tendency of being increased with the reduction of the width of a micro contact. It is increased with the reduction of the boundary film–contact interfacial shear strength or with the increase of the critical boundary film thickness, while it is strongest at certain values of the contact surface roughness, the width ratio of fluid film area to boundary film area, and the lubricant film shear elastic modulus.

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A comparative study of constant-voltage and constant-temperature hot-wire anemometers: Part II – The dynamic response

The dynamic response of the constant-voltage anemometer (CVA) system was investigated both analytically and experimentally and compared to that of the CTA. The frequency response functions of the CVA system for a number of different circuit parameters and flow conditions were determined via laser-based radiative heating of the hot-wire sensor. A 2nd-order linear systems model of the CVA was developed to provide insight to the dynamic response and to interpret the experimental results. The qualitative variations in the frequency response function with changes in circuit parameters are in agreement with the model. The experimentally determined frequency-response functions of the CVA systems used in this study were found to have little dependence on the wire overheat ratio and Reynolds number.     

A rheo-optical study of shear-thickening and structure formation in polymer solutions. Part II: Light scattering analysis

Light scattering calculations based on Anomalous Diffraction Theory (AD), Rayleigh spheroids, and flexible macromolecules are used to propose a phenomenological explanation for the relationship between shear-thickening and structure formation in polymer solutions. Quantitative comparisons are made to experimental data for the rheo-optical behavior of fractionated polystyrene solutions presented in part I of this paper. Results from the ADA calculations suggest that the viscosity and dichroism behavior can be attributed to the production and growth of micron-size, optically isotropic structures during flow. The saturation dichroism behavior exhibited by the solutions which shear thin can be attributed to the formation of entanglement regions which achieve a fixed size and act as Rayleigh spheroids in their scattering behavior. The magnitude and shear rate dependence of the observed birefringence can be accounted for on the basis of the non-linear, flexible macromolecule model, implying that birefringence is governed by the polymer chains remaining in solution which do not take part in the structure formation. The latter result is consistent with the experimental observation that the birefringence dependence on shear rate is the same whether the solution exhibits shear thickening or shear thinning in its viscosity behavior.     

Non-linear least-squares solution to the moiré hole method problem in orthotropic materials. Part II: Material elastic constants

This is the second of two papers dealing with inverse problems arising from the hole method problem in orthotropic materials. Two inverse problems are of interest in this second paper: one relates to the use of the hole method as a means of separation of stresses; the other deals with using it for orthotropic material elastic constant identification. The problem of separation of stresses is posed and briefly discussed, but the orthotropic material identification problem is addressed, fully showing how to obtain the five orthotropic elastic constants, four of which are independent, when knowing the applied stresses and examining the isothetics or moiré fringes around a through hole in a biaxially loaded thin wood plate.