Computer‐Aided Design of Metal Melt Filters: Geometric Modifications of Open‐Cell Foams, Effective Hydraulic Properties and Filtration Performance

Lehmann, Henry; Werzner, Eric; Malik, Alexander; Abendroth, Martin; Ray, Subhashis; Jung, Bernhard

doi:10.1002/adem.202100878

Cited by 7 publications

(1 citation statement)

References 23 publications

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“…Initially, the Forchheimer equation was derived for steady state, incompressible fluid and a homogeneous and uniform porous medium, fully saturated with a Newtonian incompressible fluid [7]. For years, the equation has been utilized in numerous studies on open-cell metal foams [8], [9] and 3D printed foams [10], [11]. Thus, the pressure drop parameters like permeability and inertial drag coefficients are very divergent for various classes of porous media.…”

Section: Introductionmentioning

confidence: 99%

Permeability of 3D Printed Open-Cell Foam Produced Using Selective Laser Sintering

Anuar,

Saat,

Mohd Zini

et al. 2023

KEM

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3D printing technology has gained popularity among researchers since it can produce complex geometries, such as open-cell foam. The open-cell foam shows potential in a range of applications such as energy absorption, thermal management, filtering, and acoustic damping. However, the feasibility of the applications depends on the material used to construct the 3D printed open-cell foam and its physical properties e.g, pore size and porosity. Therefore, understanding the physical properties is crucial in classifying this new generation of open-cell foams. This study aims to determine the permeability of 3D printed foams using the Forchheimer equation and compared the results with a fractional estimation method to reduce the duration of future experiments. The fractional results were validated through computational fluid dynamics (CFD) simulations. The result shows that the proposed estimation method can be used to determine the permeability of 3D printed foam with a height of 60 mm or larger, and up to six times larger than 5 PPI (pores per inch). However, it is recommended to conduct simulations of large pore size foam using a 3D model to accurately describe the local velocities in the free stream region.

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Section: Introductionmentioning

confidence: 99%

Permeability of 3D Printed Open-Cell Foam Produced Using Selective Laser Sintering

Anuar,

Saat,

Mohd Zini

et al. 2023

KEM

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Large Eddy Simulation of Turbulent Flow and Inclusion Transport during Filtration of Liquid Steel inside Open‐Cell Ceramic Foams

et al. 2021

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The present numerical investigation is conducted to improve the understanding of the physical processes, encountered during the filtration of steel melt. For this purpose, the process conditions in a pouring experiment are considered. The effects of increasing either the superficial melt velocity or the pore count of the filter are studied. The turbulent flow is modeled using the large eddy simulation in the context of the lattice Boltzmann method and the motion of nonmetallic inclusions is predicted using discrete Lagrangian particle tracking. The simulations show that turbulent flow develops as the melt advances through the filter, with the length scale of the smallest flow structures lying in the same order as the particle size. The pressure drop and the filtration coefficient are found to agree with the previous studies.

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Simulation of Fluid Flow, Heat Transfer and Particle Transport Inside Open-Cell Foam Filters for Metal Melt Filtration

Werzner,

Mendes,

Demuth

et al. 2024

Springer Series in Materials Science

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In order to develop improved filters for metal melt filtration, different physical phenomena that take place during depth filtration of liquid metals need to be well understood. Due to the difficult accessibility of the process, the harsh process conditions and the randomness of the typically employed ceramic foam filters, representative experimental investigations are extremely difficult to perform and often provide only integral quantities or selective information. This chapter presents a numerical model for simulating the depth filtration of liquid metal at the pore-scale, i.e., fully resolving the complex filter geometry, which can also accurately handle the curved filter walls. In the model, the velocity and pressure distribution of the melt flow is obtained by the lattice-Boltzmann method and the temperature field is calculated using the finite volume method, while the transport and filtration of the inclusions are predicted by solving the equation of motion for particles in a Lagrangian reference frame. In order to obtain a consistent representation of the curved filter walls for both particle transport and fluid flow, the Euclidean distance field of the filter structures is employed. By comprehensive parametric studies, the sensitivity of the filtration process with respect to various geometric parameters and process conditions is investigated. Therefore, geometries of conventionally manufactured filters, acquired from 3D μCT scanning, as well as computer-generated filter structures are considered. Their performance is assessed by evaluating various effective properties, such as the viscous and inertial permeability and the filtration coefficient. The numerical predictions allow to draw conclusions with respect to the dominant physical mechanisms and are compared with those from simplified physical models, which are shown to be sufficiently accurate for the pre-screening of filters. On the basis of the detailed results, suggestions for improved filter geometries are made, depending on the considered filtration process. Further, simplified models for the prediction of the effective thermal conductivity of open-cell foams in presence and absence of radiation are presented and validated using the detailed numerical predictions.

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Computer‐Aided Design of Metal Melt Filters: Geometric Modifications of Open‐Cell Foams, Effective Hydraulic Properties and Filtration Performance

Abstract: The ORCID identification number(s) for the author(s) of this article can be found under https://doi.org/10.1002/adem.202100878.

Cited by 7 publications

References 23 publications

Permeability of 3D Printed Open-Cell Foam Produced Using Selective Laser Sintering

Permeability of 3D Printed Open-Cell Foam Produced Using Selective Laser Sintering

Large Eddy Simulation of Turbulent Flow and Inclusion Transport during Filtration of Liquid Steel inside Open‐Cell Ceramic Foams

Simulation of Fluid Flow, Heat Transfer and Particle Transport Inside Open-Cell Foam Filters for Metal Melt Filtration

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