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

Zarzalejo, L. J.; Schmaltz, Kevin; Amón, Cristina H.

doi:10.1007/s002310050285

Cited by 50 publications

(20 citation statements)

References 18 publications

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“…Fig. 4 The impact of fusion depth on inclined angle θ (º) of pillars at different offset ratios ξ Heat transfer between the impinging droplet and solidified droplet can be modeled as a twophase one dimensional Stefan melting problem [17], as shown in appendix. The position of the melting interface X(t) is shown in…”

Section: Resultsmentioning

confidence: 99%

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Direct fabrication of unsupported inclined aluminum pillars based on uniform micro droplets deposition

Zhang

Luo

et al. 2017

International Journal of Machine Tools and Manufacture

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Section: Resultsmentioning

confidence: 99%

“…Droplet fusion is a complicated fluid and thermal behavior, which includes impacting [15], spreading [16], re-melting [17], oscillation [18] and solidification [19] of metal droplets. Low Weber number deposition is a prerequisite to maintain the droplet spreading controllable [18].…”

Section: Introductionmentioning

confidence: 99%

Direct fabrication of unsupported inclined aluminum pillars based on uniform micro droplets deposition

Zhang

Luo

et al. 2017

International Journal of Machine Tools and Manufacture

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“…The 3D printing and rapid prototyping (RP) technology by successive deposition metal droplets are an additive process, and the components are manufactured from molten metal materials in a single operation without the use of a mold or other tooling. Near net shape parts are fabricated by sequentially depositing molten droplets layer by layer [2]. Up to now, the generation of molten metal droplets has been developed into two main modes: continuous jetting [3][4][5][6][7][8] and drop-on-demand (DOD) jetting [9,10].…”

Section: Introductionmentioning

confidence: 99%

“…Currently, the simulation works related to droplet deposition and fusion processes are mainly based on 2D models, which focus on the normal impinging of single droplet onto a fixed substrate surface [12][13][14][15][16][17][18][19][20][21]. However, 2D models could not provide comprehensive details of the deposition process.…”

Section: Introductionmentioning

confidence: 99%

Fusions between Successive Deposition Droplets Impinging on a Moving Substrate Surface

Li¹,

Yang²,

Gao³

et al. 2017

Proceedings of the 2017 International Conference on Material Science, Energy and Environmental Engineering (MSEEE 2017)

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Abstract. Successive deposition of uniform metal droplet is a new kind of 3D printing and rapid prototyping (RP) technology. Broad interests have been aroused in the deposition of metal droplets due to its potential application in microstructures fabrication. In this paper, the 3D models based on a volume of fluid (VOF) method were developed to investigate the successive deposition of molten metal droplets on a horizontally moving aluminum substrate surface and manufactured the typical thin-walled parts using the process of metal droplet deposition. The impinging, spreading and fusion processes of droplets were investigated under uniform substrate velocities. The simulated final morphology of droplets agreed well with experiments carried out under the same conditions. It was found that the molten metal droplets solidified in a layer by layer from the outer to the inner due to the high heat conductivity. A series of arc-shaped ridges appeared on the surface of solidified droplets, which resulted from the integrated effects from solidification and fusion consisting of alternately spreading and fusion of droplets. The works should be helpful for the process optimization and non-destructive detection of drop-based rapid prototyping techniques.

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“…This makes them suitable for process optimization against parameters such as final droplet diameter. More complex models solve the Navier-Stokes and heat-energy governing equations on a spatial mesh [11][12][13][14]. These can provide insight into the solidification process by providing details of the transient temperature distributions and fluid flows within the droplet and substrate that are not accessible experimentally.…”

Section: Introductionmentioning

confidence: 99%

Adhesion of Precision Welded Lead-Free Electrical Interconnects Formed by Molten Droplet Deposition

Webb

Liu

Sarvar

et al. 2007

Proceedings of the Institution of Mechanical Engineers, Part B:

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This item was submitted to Loughborough's Institutional Repository (https://dspace.lboro.ac.uk/) by the author and is made available under the following Creative Commons Licence conditions.For the full text of this licence, please go to: http://creativecommons.org/licenses/by-nc-nd/2.5/ Adhesion of precision welded lead-free electrical interconnects formed by molten droplet deposition D P Webb*, C Liu, F Sarvar, P P Conway, and K Williams School of Mechanical and Manufacturing Engineering, Loughborough University, Loughborough, UKThe manuscript was received on 18 April 2005 and was accepted after revision for publication on 25 October 2006. DOI: 10.1243/09544054JEM365Abstract: An existing process, droplet welding, has been proposed for the production of precision, high-temperature, lead-free electrical joints. A modified metal inert gas (MIG) welding plasma is used to produce molten metal droplets, which then fall on a part to make an electrical joint. The subject of the present paper is an investigation of the factors affecting successful welded joint formation for a given droplet material and target, with the goal of providing the basis of a computer model to enable rapid process set-up on a production line. It is found that a parameter space can be identified for good adhesion of a droplet to a target, characterized by droplet temperature and target thickness, for each droplet material/target material combination. Essentially adhesion can be viewed as determined by competition between the delivery of thermal energy from the droplet to the target immediately underneath the droplet, and the removal of the energy from the interface region to the rest of the target, with no role played by the droplet kinetics after impact. It is therefore concluded that a relatively simple thermal model could be used by production-line engineers to identify the parameter space for rapid process set-up with new material combinations and products. The conclusion is supported by evidence from high-speed video images of droplet impact. Such a simple thermal model is proposed and is found to be capable of predicting adhesion between droplet and target. The results are discussed in the context of the extensive literature on molten droplet impact and solidification.

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

Cited by 50 publications

References 18 publications

Direct fabrication of unsupported inclined aluminum pillars based on uniform micro droplets deposition

Direct fabrication of unsupported inclined aluminum pillars based on uniform micro droplets deposition

Fusions between Successive Deposition Droplets Impinging on a Moving Substrate Surface

Adhesion of Precision Welded Lead-Free Electrical Interconnects Formed by Molten Droplet Deposition

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