Thermo-mechanical homogenisation – application to HVOF thermal-sprayed WC-Co coatings

Hard material coatings are widely employed as wear protection for highly engrossed surfaces. For example, coatings consisting of tungsten carbide (WC) and cobalt (Co) are used for sheet metal forming tools. A relatively cost-efficient coating technique is the high velocity oxygen fuel (HVOF) thermal spraying process which, as a trade-off, induces a large amount of energy into the heterogeneous coating and the substrate. Hence, this leads to a complex transient, thermomechanically coupled problem. In order to predict the residual stresses during the quenching procedure, a two scale finite element framework is established wherein the scale bridging is performed by application of two different homogenisation approaches. (© 2014 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Inverse heat conduction problem in a thin circular plate and its thermal deflection

An inverse problem of transient heat conduction in a thin finite circular plate with the given temperature distribution on the interior surface of a thin circular plate being a function of both time and position has been solved with the help of integral transform technique and also determine the thermal deflection on the outer curved surface of a thin circular plate defined as 0 ? r ? a, 0 ? z ? h. The results, obtained in the series form in terms of Bessel’s functions, are illustrated numerically.     

Analysis of flow and thermal field in nanofluid using a single phase thermal dispersion model

Flow and thermal field in nanofluid is analyzed using single phase thermal dispersion model proposed by Xuan and Roetzel [Y. Xuan, W. Roetzel, Conceptions for heat transfer correlation of nanofluids, Int. J. Heat Mass Transfer 43 (2000) 3701–3707]. The non-dimensional form of the transport equations involving the thermal dispersion effect is solved numerically using semi-explicit finite volume solver in a collocated grid. Heat transfer augmentation for copper–water nanofluid is estimated in a thermally driven two-dimensional cavity. The thermo-physical properties of nanofluid are calculated involving contributions due to the base fluid and nanoparticles. The flow and heat transfer process in the cavity is analyzed using different thermo-physical models for the nanofluid available in literature. The influence of controlling parameters on convective recirculation and heat transfer augmentation induced in buoyancy driven cavity is estimated in detail. The controlling parameters considered for this study are Grashof number (10³ < Gr < 10⁵), solid volume fraction (0 < ? < 0.2) and empirical shape factor (0.5 < n < 6). Simulations carried out with various thermo-physical models of the nanofluid show significant influence on thermal boundary layer thickness when the model incorporates the contribution of nanoparticles in the density as well as viscosity of nanofluid. Simulations incorporating the thermal dispersion model show increment in local thermal conductivity at locations with maximum velocity. The suspended particles increase the surface area and the heat transfer capacity of the fluid. As solid volume fraction increases, the effect is more pronounced. The average Nusselt number from the hot wall increases with the solid volume fraction. The boundary surface of nanoparticles and their chaotic movement greatly enhances the fluid heat conduction contribution. Considerable improvement in thermal conductivity is observed as a result of increase in the shape factor.     

Numerical study of melting in an enclosure with discrete protruding heat sources

In order to explore the capability of a solid–liquid phase change material (PCM) for cooling electronic or heat storage applications, melting of a PCM in a vertical rectangular enclosure was studied. Three protruding generating heat sources are attached on one of the vertical walls of the enclosure, and generating heat at a constant and uniform volumetric rate. The horizontal walls are adiabatic. The power generated in heat sources is dissipated in PCM (n-eicosane with the melting temperature, T_m = 36 °C) that filled the rectangular enclosure. The advantage of using PCM is that it is able to absorb high amount of heat generated by heat sources due to its relatively high energy density. To investigate the thermal behaviour and thermal performance of the proposed system, a mathematical model based on the mass, momentum and energy conservation equations was developed. The governing equations are next discretised using a control volume approach in a staggered mesh and a pressure correction equation method is employed for the pressure–velocity coupling. The PCM energy equation is solved using the enthalpy method. The solid regions (wall and heat sources) are treated as fluid regions with infinite viscosity and the thermal coupling between solid and fluid regions is taken into account using the harmonic mean of the thermal conductivity method. The dimensionless independent parameters that govern the thermal behaviour of the system were next identified. After validating the proposed mathematical model against experimental data, a numerical investigation was next conducted in order to examine the thermal behaviour of the system by analyzing the flow structure and the heat transfer during the melting process, for a given values of governing parameters.     

Numerical analysis of the thermal behaviour of a shell-and-tube heat storage unit using phase change materials

This work presents a numerical study of a latent heat storage unit (LHSU) consisting of a shell-and-tube. The shell space is filled with two phase change materials (PCMs), P116 and n-octadecane, with different melting temperatures (50 °C and 27.7 °C, respectively). A heat transfer fluid (HTF: water) flows by forced convection through the inner tube, and transfers the heat to PCMs. In order to compare the thermal performances of the latent heat storage unit using two phase change materials (LHSU2) and a single PCM (LHSU1), a mathematical model based on the conservation energy equations was developed and validated with experimental data. Several numerical investigations were conducted in order to examine the impact of the key parameters: the HTF inlet temperature (ranges from 50 to 60 °C), the mass flow rate of the HTF and the proportion mass of PCMs, on the thermal performances of the latent heat storage units using two PCMs and a single PCM, during charging process (melting). This parametric study provides guidelines for system thermal performance and design optimization.     

Application of a cohesive zone element for the prediction of damage in nano/micro coating

Many tools in production technology are nowadays coated to obtain a satisfactory lifetime and degradation resistance. Therefore, the main goal of this study is to investigate antiadhesive and wear resistant coatings made of ceramics, plastics and metals produced by High Power Pulsed Magnetron Sputtering (HPPMS) technique [1]. A cohesive zone element technique (CZ) is applied to model the interactions of the coatings and the substrate surfaces (see [2]). This goes along with the investigations of the delamination and failure behavior of the involved surfaces. To illustrate the applicability of the model, several structural simulations are performed. The developed CZ element model is capable of modeling the separation, the contact and also the irreversible reloading conditions in both normal and tangential directions [3]. The model is further developed to be applicable for different structures including different bonding behaviors, with a higher stability. The talk concludes with a detailed discussion of the numerical results of different material and interface properties. (© 2015 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Parameter extension for combined hybrid finite element methods and application to plate bending problems

Based on a weighted average of the modified Hellinger-Reissner principle and its dual, the combined hybrid finite element (CHFE) method was originally proposed with a combination parameter limited in the interval (0, 1). In actual computation this parameter plays an important role in adjusting the energy error of discretization models. In this paper, a novel expression of the combined hybrid variational form is used to show the relationship between the resultant method and some Galerkin/least-squares stabilized finite scheme for plate bending problems. The choice of combination parameter is then extended to (−∞, 0) ? (0, 1). Existence, uniqueness and convergence of the solution of discrete schemes are proved, and the advantage of the parameter extension in computation is discussed. As an application, improvement of Adini’s rectangular element by the CHFE approach is performed.     

Computation of melting with natural convection inside a rectangular enclosure heated by discrete protruding heat sources

This paper presents the results of a numerical investigation of the heat transfer by natural convection during the melting of a phase change material (PCM, n-eicosane with melting point of 36 °C) contained in a rectangular enclosure. This latest is heated by three discrete protruding heat sources (simulating electronic components) placed on one of its vertical walls. The power generated by heat sources is dissipated in PCM. The advantage of using this cooling scheme is that the PCMs are able to absorb high amount of heat generated by the heat sources, without acting the fan during the charging process (melting of the PCM). The thermal behavior and thermal performance of the proposed PCM based-heat sink are numerically investigated by developing a mathematical model based on the mass, momentum and energy conservation equations. The obtained numerical results show the impact of various key parameters on the cooling capacity of the PCM-based heat sink. Correlations encompassing a wide range of parameters were developed in terms of the dimensionless secured operating time (time required by one of the electronic components before reaching its critical temperature, T_cr ∼ 75 °C) and the corresponding liquid fraction, using the asymptotic computational fluid dynamics (ACFD) technique.     

The study of structure optimization of blast furnace cast steel cooling stave based on heat transfer analysis

The three-dimensional mathematical model of temperature and thermal stress field of cast steel cooling stave in a blast furnace has been modeled. Kinds of the parameters optimization of cast steel cooling stave in a blast furnace are proposed based on the heat transfer analysis. The results indicate that the values of the parameters optimization for a cast steel cooling stave are 200 mm for cooling channels interdistance, 25 mm for inner radius of the water channel, 180 mm for thickness of the cooling stave body, 70 mm for thickness of inlaid brick and 1.5 m/s for speed of cooling water. Reducing the water temperature would be uneconomical. The water temperature can be chosen according to the local conditions. The best choice for lining material is silicon nitrogen bond silicon carbide brick or silicon carbide brick.     

Superconvergence of a discontinuous finite element method for a nonlinear ordinary differential equation

In this paper, n-degree discontinuous finite element method with interpolated coefficients for an initial value problem of nonlinear ordinary differential equation is introduced and analyzed. By using the finite element projection for an auxiliary linear problem as comparison function, an optimal superconvergence , at (n + 1)-order characteristic points in each element respectively is proved. Finally the theoretic results are tested by a numerical example.     

Evaluation of thermal comfort conditions in a classroom equipped with radiant cooling systems and subjected to uniform convective environment

The aim of this work is to evaluate numerically the human thermal response that 24 students and 1 teacher feel in a classroom equipped with radiant cooling systems and subjected to uniform convective environments, in lightly warm conditions. The evolution of thermal comfort conditions, using the PMV index, is made by the multi-nodal human thermal comfort model.In this numerical model, that works in transient or steady-state conditions and simulates simultaneously a group of persons, the three-dimensional body is divided in 24 cylindrical and 1 spherical elements. Each element is divided in four parts (core, muscle, fat and skin), sub-divided in several layers, and protected by several clothing layers. This numerical model is divided in six parts: human body thermal system, clothing thermal system, integral equations resolution system, thermoregulatory system, heat exchange between the body and the environment and thermal comfort evaluation.Seven different radiant systems are combined to three convective environments. In the radiant systems (1) no radiant system without warmed curtain, (2) no radiant system with warmed curtain, (3) radiant floors cooling system with warmed curtain, (4) radiant panels cooling system with warmed curtain, (5) radiant ceiling cooling system with warmed curtain, (6) radiant floor and panels cooling system with warmed curtain and (7) radiant ceiling and panels cooling system with warmed curtain are analysed, while in the convective environments (1) without air velocity field and with uniform air velocity field of (2) 0.2 m/s and (3) 0.6 m/s are also analysed. The internal air temperature and internal surfaces temperature are 28 °C, the radiant cooling surfaces temperature are 19 °C and the warmed internal curtains surfaces temperatures, subjected to direct solar radiation, are 40 °C.The numerical model calculates the Mean Radiant Temperature field, the human bodies’ temperatures field and the thermal comfort level, for the 25 occupants, for the 21 analysed situations.Without uniform air velocity field, when only one individual radiant cooling system is used, the Predicted Percentage of Dissatisfied people is lowest when the radiant floor cooling system is applied and is highest when the radiant panel cooling system is applied. When are combined the radiant ceiling or the floor cooling systems with the radiant panel cooling system the Predicted Percentage of Dissatisfied people decreases.When the uniform air velocity increases the thermal comfort level, that the occupants are subjected, increases. When the radiant floor cooling system or the combination of radiant floor and panel cooling systems without uniform air velocity field is applied, the Category C is verified for some occupants. However, with a convective uniform air velocity field of 0.2 m/s the Category B is verified and with a convective uniform air velocity field of 0.6 m/s the Category A is verify for some occupants. In the last situation the Category C is verified, in general, for all occupants.     

A geometrically nonlinear finite element model of nanomaterials with consideration of surface effects

In conventional continuum mechanics, the surface energy is usually small and negligible. But at nano-length scale, it becomes a significant part of the total elastic energy due to the high specific surface area of nanomaterials. A geometrically nonlinear finite element (FE) model of nanomaterials with considering surface effects is developed in this paper. The aim is to extend the conventional finite element method (FEM) to analyze the size-dependent mechanical properties of nanomaterials. A numerical example, analysis of InAs quantum dot (QD) on GaAs (0 0 1) substrate, is given in this paper to verify the validity of the method and demonstrate surface effects on the stress fields of QDs.     

Isospectral flows that preserve matrix structure

The matrix A = (a_ij) ∈ S_n is said to lie on a strict undirected graph G if a_ij = 0 (i ≠ j) whenever (i, j) is not in E(G). If S is skew-symmetric, the isospectral flow maintains the spectrum of A. We consider isospectral flows that maintain a matrix A(t) on a given graph G. We review known results for a graph G that is a (generalised) path, and construct isospectral flows for a (generalised) ring, and a star, and show how a flow may be constructed for a general graph. The analysis may be applied to the isospectral problem for a lumped-mass finite element model of an undamped vibrating system. In that context, it is important that the flow maintain other properties such as irreducibility or positivity, and we discuss whether they are maintained.     

Use of geometry in finite element thermal radiation combined with ray tracing

In heat transfer for space applications, the exchanges of energy by radiation play a significant role. In this paper, we present a method which combines the geometrical definition of the model with a finite element mesh. The geometrical representation is advantageous for the radiative component of the thermal problem while the finite element mesh is more adapted to the conductive part. Our method naturally combines these two representations of the model. The geometrical primitives are decomposed into cells. The finite element mesh is then projected onto these cells. This results in a ray tracing acceleration technique. Moreover, the ray tracing can be performed on the exact geometry, which is necessary if specular reflectors are present in the model. We explain how the geometrical method can be used with a finite element formulation in order to solve thermal situation including conduction and radiation. We illustrate the method with the model of a satellite.     

Non-linear analysis and calculation of the performance of a shelving protection system by FEM

The aim of this paper consists on the study, analysis and calculation of the efficiency of a shelving protection system by means of the finite element method (FEM). These shelving protection systems are intended to prevent the eventual damage due to the impacts of transport elements in motion, such as: forklifts, dumpers, hand pallet trucks, and so on. The impact loads may threaten the structural integrity of the shelving system. The present structural problem is highly non-linear, due to the simultaneous presence of the following nonlinearities: material non-linearity (plasticity in this case), geometrical non-linearity (large displacements) and contact-type boundary conditions (between the rigid body and the protection system). A total of 48 different FEM models are built varying the thickness of the steel plate (4, 5 and 6 mm), the impact height (0.1, 0.2, 0.3 and 0.4 m) and the impact direction (head-on collision and side impact). Once the models are solved, the stress distribution, the overall displacements and the absorbed impact energy were calculated. In order to determine the best shelving protection’s candidate, some constraints must be taken into account: the maximum allowable stress (235 MPa), the maximum displacement (0.05 m) and the absorbed impact energy (400 J according to the European Standard Rule PREN-15512). Finally, the most important results are shown and conclusions of this study are exposed.     

Towards a finite element simulation of coating by means of thermal spraying

Metal sheet forming processes like deep drawing are applied in order to produce carriage parts in mass production. Therefore, forming tools are required that are well protected against wear. For such forming tools, wear resistant surfaces are, e.g., produced by thermal spraying of hard material coatings. The thermal spraying process itself is a highly transient thermo-mechanical process. In order to gain a better understanding of the heat input and transfer during thermal spraying, a simulation framework for thermal spraying processes is presented. (© 2015 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Optimal paths for minimizing entransy dissipation during heat transfer processes with generalized radiative heat transfer law

A common of finite-time heat transfer processes between high- and low-temperature sides with generalized radiative heat transfer law [q ∝ Δ(Tⁿ)] is studied in this paper. In general, the minimization of entropy generation in heat transfer processes is taken as the optimization objective. A new physical quantity, entransy, has been identified as a basis for optimizing heat transfer processes in terms of the analogy between heat and electrical conduction recently. Heat transfer analyses show that the entransy of an object describes its heat transfer ability, as the electrical energy in a capacitor describes its charge transfer ability. Entransy dissipation occurs during heat transfer processes, as a measure of the heat transfer irreversibility with the dissipation related thermal resistance. Under the condition of fixed heat load, the optimal configurations of hot and cold fluid temperatures for minimizing entransy dissipation are derived by using optimal control theory. The condition corresponding to the minimum entransy dissipation strategy with Newtonian heat transfer law (n = 1) is that corresponding to a constant heat flux rate, while the condition corresponding to the minimum entransy dissipation strategy with the linear phenomenological heat transfer law (n = −1) is that corresponding to a constant ratio of hot to cold fluid temperatures. Numerical examples for special cases with Newtonian, linear phenomenological and radiative heat transfer law (n = 4) are provided, and the obtained results are also compared with the conventional strategies of constant heat flux rate and constant hot fluid (reservoir) temperature operations and optimal strategies for minimizing entropy generation. Moreover, the effects of heat load changes on the optimal hot and fluid temperature configurations are also analyzed.     

Numerical study of heat transfer enhancement in mixed convection flow along a vertical plate with heat source/sink utilizing nanofluids

Steady, mixed convection laminar boundary layer flow of incompressible nanofluid along the vertical plate with temperature dependent heat source/sink has been investigated numerically. The resulting non-linear governing equations (obtained with the Boussinesq approximation) are solved, using a robust, extensively validated, variational finite element method (FEM) for both spherical and cylindrical shaped nanoparticles with volume fraction ranging up to 4%, with associated boundary conditions and the effect of the parameters governing the problem are discussed. Different water-based nanofluids containing Cu, Ag, CuO, Al₂O₃, and TiO₂ are taken into consideration. The results show that the average Nusselt number is found to decrease for Ag, Cu, CuO, Al₂O₃, and TiO₂. The present study is of immediate interest in next-generation solar film collectors, heat exchangers technology, materials processing exploiting vertical surfaces, geothermal energy storage and all those processes which are highly affected with heat enhancement concept.     

Modeling and analysis of vaporizing during vacuum electron beam welding on magnesium alloy

The vaporizing model of vacuum electron beam welding on magnesium alloy is developed based on the laws of heat conduction and energy conservation. The vaporizing time of the main metal elements in AZ series magnesium alloy is calculated using the model. The results show that the vaporization of Mg element will precede the Zn element under the affecting of high energy density electron beam. The vaporizing times of alloying elements are not entirely dependent on the level of the boiling point, also dependent on the thermal diffusivity and are closely related to the latent heat of vaporizing and melting of the materials. The change of beam spot diameter of electron beam also greatly alters the heat transfer characteristics of electron beam heat source. As the strong vaporizing effect of Mg element will occur within several milliseconds, the keyhole induced by the metal elements vaporizing is formed only within several milliseconds, but also the deep penetration welding effect of vacuum electron beam welding on magnesium alloys will be obtained in a very short period of time.     

Axi symmetric 2D simulation and numerical heat transfer characteristics for the calibration furnace in a rectangular enclosure

This paper presents axi symmetric 2D numerical investigation of the spherical thermocouple calibration furnace in a rectangular enclosure. The focus is on the flow structure inside the Saturn (a hollow spherical cavity), external flow behavior due to annulus block heating and the surface temperature uniformity. Mesh sensitivity analysis is adopted to extract the mesh with minimum number of nodes but with fast convergent finite element solution. The basic strategy here is that temperature perturbation error at a single point instead of a single element contributed to the total perturbation error qualitatively remains the same. Agreement between numerical simulation results and the experiment results is good with a maximum temperature deviation 10 °C for the cavity temperature 400 °C. Finally, standard numerical temperature uncertainty due to variation in thermal conductivity is computed through the sensitivity coefficient using uncertainty analysis.