Towards additive manufacturing of compressor impellers: 3D modeling of multilayer laser solid freeform fabrication of nickel alloy 625 powder mixed with nano-CeO 2 on AISI 4140

Fayaz, G.R.; Kazemzadeh, Saman

doi:10.1016/j.addma.2018.02.001

Cited by 11 publications

(5 citation statements)

References 16 publications

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“…From a computational point of view, an evaporation process is a problem with a moving boundary, since the liquid thickness decreases over time (ℎ =ℎ ( )). COMSOL Multiphysics is able to deal with moving boundaries [84][85][86] and the Arbitrary Lagrangian-Eulerian (ALE) module implemented in COMSOL Multiphysics was used to manage the moving interface [76]. The phase field model and the temperature equation have been coupled with moving mesh, allowing an automatic remeshing procedure during the time evolution of the physical domain.…”

Section: Numerical Implementationmentioning

confidence: 99%

Influence of evaporation on the morphology of a thin film of a partially miscible binary mixture

Rabani

Sadafi

Machrafi

et al. 2021

Colloids and Surfaces A: Physicochemical and Engineering Aspect

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In this paper, we develop numerical, theoretical and experimental analyses of the different morphologies that can be created by the phase separation phenomena that are induced by solvent evaporation in a thin film of a partially miscible binary mixture. Disregarding hydrodynamic effects, the Cahn-Hilliard-Cook and temperature equations are used to describe the thermodynamics of non-isothermal phase separation in a 2D thin film. Numerical simulations are performed to investigate the interplay between evaporation and phase separation and we examine the effect on the morphology of the film of several parameters such as the initial thickness of the layer, or the initial temperature and concentration of the mixture. Interestingly, the competition between evaporation and phase separation is shown to be the main determinant of the choice between a lamellar or a lateral pattern in the beginning of phase separation. For moderate evaporation rate, the spinodal instability takes place close to the evaporating interface and a lateral structure is formed. For stronger evaporation, the spinodal instability does not occur and a lamellar structure is created. In addition, the mid-or long-term evolution of the system is also considered. The thickness of the film is an important parameter in this analysis and possible modifications of the pattern over time are emphasized. Detailed physical and theoretical interpretations are proposed for the results and experiments in a Hele-Shaw cell that nicely confirm our predictions are presented.

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Section: Numerical Implementationmentioning

confidence: 99%

Influence of evaporation on the morphology of a thin film of a partially miscible binary mixture

Rabani

Sadafi

Machrafi

et al. 2021

Colloids and Surfaces A: Physicochemical and Engineering Aspect

View full text Add to dashboard Cite

show abstract

“…They allow one to obtain the best material distribution within a given design space, fixing the problem conditions (loads and constraints), to meet a predefined set of performance objectives [7][8][9][10][11][12][13][14]. The possibility of combining AM techniques with topology optimization represents a convenient choice because of the great geometrical freedom, combined with minimum attention to fabrication constraints, that can be provided by this manufacturing process [15,16]. Metal-based processes are involved in the fabrication of impellers.…”

Section: Introductionmentioning

confidence: 99%

Improving Aeromechanical Performance of Compressor Rotor Blisk with Topology Optimization

Bandini,

Cascino,

Meli

et al. 2024

Energies

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When it comes to modern design of turbomachinery, one of the most critical objectives is to achieve higher efficiency and performance by reducing weight, fuel consumption, and noise emissions. This implies the need for reducing the mass and number of the components, by designing thinner, lighter, and more loaded blades. These choices may lead to mechanical issues caused by the fluid–structure interaction, such as flutter and forced response. Due to the periodic aerodynamic loading in rotating components, preventing or predicting resonances is essential to avoid or limit the dangerous vibration of the blades; thus, simulation methods are crucial to study such conditions during the machine design. The purpose of this paper is to assess a numerical approach based on a topology optimization method for the innovative design of a compressor rotor. A fluid-structural optimization process has been applied to a rotor blisk which belongs to a one-and-a-half-stage aeronautical compressor including static and dynamic loads coming from blade rotation and fluid flow interaction. The fluid forcing is computed by some CFD TRAF code, and it is processed via time and space discrete Fourier transform to extract the pressure fluctuation components in a cyclic-symmetry environment. Finally, a topological optimization of the disk is performed, and the encouraging results are presented and discussed. The remarkable mass reduction in the component (≈32%), the mode-shape frequency shift from a fluid forcing frequency, and an overall relevant reduction in the dynamic response around Campbell’s crossing confirm the efficacy of the presented methodology.

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“…Nonetheless, TO turbomachinery applications are still documented in the scientific literature, although limited occurrences can be found (e.g. [3]- [5]). For the interested reader, [6] offers a full review on the topic.…”

Section: Introductionmentioning

confidence: 99%

Topology Optimization of Static Turbomachinery Components

Meli¹,

Secciani²,

Ridolfi³

et al. 2023

Manufacturing Technology

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Additive Manufacturing has enabled the design of complex components in several technical fields. Considering turbomachinery components, additive manufacturing has unlocked the achievement of significant performances for dynamic rotoring components. The application of topology optimization methods is one of the main factors accelerating the technological development of this sector. This paper presents a procedure for the optimization of static turbomachinery components. The framework proposed compares the results obtained by introducing a lattice structure and a solid optimized shape. The procedure is presented with reference to a specific case study. To validate the proposed framework, the complete re-design of a thrust collar of a major Italian-based Oil&Gas company is carried out, demonstrating that the re-thinking of the component in terms of Topology Optimization is a straightforward approach to increase the overall performance of the produced part.

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Towards additive manufacturing of compressor impellers: 3D modeling of multilayer laser solid freeform fabrication of nickel alloy 625 powder mixed with nano-CeO 2 on AISI 4140

Cited by 11 publications

References 16 publications

Influence of evaporation on the morphology of a thin film of a partially miscible binary mixture

Influence of evaporation on the morphology of a thin film of a partially miscible binary mixture

Improving Aeromechanical Performance of Compressor Rotor Blisk with Topology Optimization

Topology Optimization of Static Turbomachinery Components

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