基于因次分析的气动系统结露问题的研究

本文利用因次分析法研究影响气动系统中结露的因素,并结合实验分析气动系统中的结露现象,给出不同系统中结露的影响因素及模型,提出一种气动系统结露的新的研究方法。     

往复扫描喷射沉积过程中雾化器运动的研究

雾化器运动是雾化器往复扫描喷射沉积过程中一个非常重要的因素。研究了雾化器往复扫描喷射沉积过程中雾化器的运动，总结了不同的喷射距离下，雾化器喷射密度函数的分布以及雾化器在扫描过程中运动速度v与沉积锭坯半径R之间的关系。在雾化器往复扫描喷射沉积过程中，根据对雾化器运动的研究进行数值模拟，实现了喷射沉积过程的工艺优化，为进一步研究喷射沉积过程提供了理论依据，对于工业生产也具有指导意义。     

基于Labview的电火花自动沉积监控系统设计

电火花沉积可制备硬度高、耐磨性和耐腐蚀性优异的强化涂层,能显著提高机械零部件的性能和使用寿命,传统电火花沉积主要依靠人工操作.基于Labview开发平台设计了一套电火花自动沉积监控系统,其硬件主要由PC机、Arduino控制卡、步进电机等组成,该系统具有运动控制、运动反馈、数据采集、沉积轨迹设置和显示等功能,并在沉积路径规划中加入了Bresenham算法,实现了电火花沉积过程的自动控制.     

金属直薄壁件激光直接沉积过程的有限元模拟Ⅱ.沉积过程中热应力场的模拟

建立了按激光光斑直径逐点沉积热力耦合的热应力有限元分析模型．316L不锈钢直薄壁件沉积过程的热应力模拟结果显示,拉应力区出现在基板与沉积部分界面处（界面拉应力区）和沉积部分顶部（顶部拉应力区）;拉应力区的位置随激光束的运动不断变化．实验证明,沉积过程中的开裂分别发生在沉积部分顶部（顶部开裂）和基板与沉积部分界面处的边缘部位（边缘开裂）．顶部开裂出现在顶部拉应力区,边缘开裂出现在界面拉应力区中拉应力最大的边缘部位．有限元模拟结果很好地解释了实验中的开裂现象．     

金属熔滴连续沉积、凝固重叠工艺及实验验证

金属熔滴均匀连续沉积是一种新型的3D打印技术和快速原型(RP)技术。本文系统研究了铝熔滴连续沉积到基板表面的瞬态传热传质现象,沉积机理主要包括金属熔体的毛细现象及固液界面的传热、凝固、搭接和重熔。采用VOF方法对连续沉积的金属熔滴在水平固定铝基板表面沉积进行3D建模。针对凝固传热过程中不同参数下熔滴在铝基板表面沉积、凝固进行了研究,通过数值计算与实验验证,各种工艺参数的影响,如喷射速度、基板温度、熔滴直径与碰撞最大铺展因子的影响,显示了很好的一致性。基于上述研究,成形形貌和内部微观结构之间的定量关系进一步验证了金属熔滴连续沉积、凝固重叠工艺的可行性。此工艺为金属微沉积制造实施有效的过程控制提供指导。     

铝合金微滴打印沉积制造中热应力3D动态仿真分析研究

翘曲、分层、开裂是7075铝合金微熔滴沉积制造过程中常见的缺陷,其原因主要是沉积制造过程中存在较大的温度梯度和热应力集中。为了探究热变形、翘曲和开裂的形成机理,采用有限单元法和单元生死技术,通过ＡＰＤＬ(ANSYS)编程,建立了气动按需熔滴沉积成形温度和热应力计算模型,分析了7075铝合金微熔滴逐点、逐层沉积三维制件过程中温度和热应力的动态演变规律。并使用7075铝合金微滴,在相同初始边界条件和工艺参数下进行了沉积试验,模拟结果与7075铝合金制件微熔滴沉积试验结果基本吻合,较好地反映了实际成形过程中零件的温度和热应力场变化规律,为减少或消除铝合金微熔滴沉积制造过程的缺陷提供了理论依据,从而促进了该技术在高熔点合金零件制备中的应用。     

金刚石的嵌入对其复合镀层的影响分析

金属-金刚石共沉积复合镀层,在不同应用领域(如提高耐磨性、自润滑性、切削性及弥散强化效果等)已得到广泛关注.详述了金刚石的嵌入对复合镀层的影响及其原因.试验发现,金刚石的嵌入恶化了复合镀层胎体的微观结构,使得胎体晶粒粗化、镀层和颗粒结合部出现间隙、镀层表面起伏不平并出现节瘤、沟谷及金刚石颗粒表面的过度包镶等现象.分析发现,以上现象是金刚石晶体内部金属包裹体的磁性,对运动的阳离子产生洛仑兹力作用,从而影响电沉积过程的结果.     

气动系统结露现象判别软件的开发研究

本文阐述了气动系统的结露问题的研究和开发相应的判别软件的重要性的必要性。针对气动系统的具体情况开发了结露判别软件DEW2000,并阐述了其主要的理论、设计思想、介绍了软件的特点,功能及软/硬件环境。并将本软件的结果与实验结果相比,验证了其结果的正确性。     

金属铜电沉积过程中分形研究

以环形金属铜片作为阳极，细铜丝作为阴极，研究了酸性电解液条件下金属铜电沉积过程中的二级枝晶生长现象，测定了沉积时间－电流关系曲线，对外加电压，电解液中硫酸铜浓度等对金属铜的电沉积产物形貌及其分维数的影响进行了观测，分析。研究发现，沉积过程中，电流随沉积时间的增加而变大，沉积产物的分维数随电解液中硫酸铜的增加而变大，随外加电压的变动而波动。     

气动挤出沉积成型材料对人工牙槽骨结构与性能的影响

以气动挤出沉积多孔生物骨支架成型机作为成型设备,以海藻酸钠(SA)与羟基磷灰石(HAP)作为成型材料,制造出了最适宜骨组织细胞生长的孔隙率和良好的内部连通结构的人工牙槽骨模型,优选了在快速成型过程中对牙槽骨质量的影响因素,并测试了在不同海藻酸钠浓度成型、不同烧结温度后处理情况下人工牙槽骨的力学性能。结果表明:当海藻酸钠浓度为5%,与羟基磷灰石的配比为1∶1.1时获得了良好的宏观外形与较优的微观孔隙结构,找到了羟基磷灰石形成骨陶瓷的最佳温度为1 200℃。     

Printing solder droplets for micro devices packages using pneumatic drop-on-demand (DOD) technique

A pneumatic drop-on-demand (DOD) system has been applied to solder complex and dense interconnects of modern micro electronic devices. Initial parameters of uniform droplets were first measured. Then influences of experiment parameters, such as the crucible temperature, the substrate temperature and the droplet velocity on spread of solder droplets, were investigated experimentally and theoretically. The results showed that effects of impact velocity on the spreading could be negligible and the solder spreading process was driven by capillary forces because of the low Weber (We) number of depositing droplet. The influence of initial droplet temperature on the droplet spreading was not regular. The contact diameter of solder droplets on copper substrate increased when the substrate temperature increased from 443 K to 493 K. At last, copper cables were successfully soldered to pins of a flexible circuit using the direct solder deposition and re-melting process. The soldering results showed the feasibility of the data-driven soldering technique using the pneumatic DOD deposition technology.     

Effect of wetting behavior on generation of uniform aluminum droplets obtained by pneumatic drop-on-demand technique

Micro metal droplet is the basic building block of three-dimensional metal parts fabricated by micro droplet deposition manufacturing (MDDM) technique. In this paper, the effect of wetting behavior between liquid metal and spray nozzle on the generation of micro aluminum droplets produced by pneumatic drop-on-demand (DOD) technique was investigated by simulation and experiment. A finite element model of liquid–gas flow was established based on the improved level set method (LSM). Then the generation of micro liquid aluminum droplets under different wetting conditions was simulated. A series of spraying experiments were also performed on micro droplet deposition experiment platform. The results show that the generation and flight of micro aluminum droplets are influenced by wetting condition between liquid metal and the nozzle surface significantly. Additionally, the effect of wetting behavior on the droplet size was analyzed to achieve the smallest building block. It was found that the droplet radius decreased with the increase of contact angle exponentially, which agreed with the numerical calculation and experiment results. On this basis, a wettability criterion was proposed for selecting nozzle materials. These works would be helpful for the processing optimization and equipment improvement of MDDM technique.     

Modeling and characterization of metal droplets generation by using a pneumatic drop-on-demand generator

A 2D axisymmetric model has been proposed to study the mechanism of the droplet generation by using a pneumatic drop-on-demand (DOD) generator. A proprietary pneumatic DOD generator was also applied to conduct droplet generation experiments. The validity of the proposed model was verified through the simulation results of droplet pattern, breakup length distance and droplet diameter, which were in good agreement with the experimental ones. Theoretical studies were conducted to characterize the metal droplet generation using pneumatic DOD technique. Theoretical analyses show that metal droplets break away from jets in front of the sphere ends due to the increase of the capillary disturbance at a very small Ohnesorge number (Oh < 0.01). This capillary disturbance is caused by the action of surface tension. Shapes of droplets do not significantly change because of the relatively low pressure inside droplets. The droplet diameter decreases when the nozzle diameter decreases to 100 μm, while the ratio of droplet diameter to nozzle diameter increases rapidly. An external disturbance with high frequency should be introduced to accelerate the metal jet breakup for further decreasing the droplet size. This work offers a useful guide for choosing appropriate parameters to generate metal droplets using pneumatic DOD technique.     

气动充放气系统中凝结现象的研究

本文利用均匀凝结理论,以气动系统中典型的充放气系统为研究对象,给出了该系统在放气过程中凝结的计算方法,分析了凝结现象的本质过程。     

Research on lateral instability of the uniform-charged droplet stream during droplet-based freeform fabrication

A droplet initial displacement assumption was made and a dynamic model of the charged droplets was developed to understand the lateral instability of the uniform-charged droplet stream for freeform fabrication. The distribution of charged droplets depending on deposition distance was obtained based on this dynamic model after the droplet charge was calculated by the FEM. Then, a droplet charging and depositing apparatus is set up to generate the uniform-charged droplet stream. The droplet charge was measured and the droplet distributions at different distances were collected in the experiment. The results show that the theoretical radius of droplet distribution area agrees well with the mean experimental value at the deposition distance of 50 cm. The theoretical trend of droplet stream dispersion fits well with experimental result. The maximum accurate deposition distance within which the radius of distribution area is less than one droplet diameter is about 27 cm according to the prediction of droplet distribution, which provides the basis for further accurate metal droplet deposition.     

Manufacturing of micro thin-walled metal parts by micro-droplet deposition

Metal micro-droplet deposition manufacturing technique is a novel direct metal rapid prototyping for building the miniaturized parts. In this paper, the novel direct metal rapid prototyping was proposed to fabricate micro thin-walled metal parts. A direct droplet fabrication experimental system was developed based on the forming principle of micro-droplet deposition manufacture. Several deposition experiments were conducted to investigate the influences of process parameters on the formed wall thickness and deposition accuracy of droplets. The experimental results show that the proper deposition distance Hs for obtaining high deposition accuracy of droplet ranges from 1 mm to 20 mm; the formed wall thickness W can be controlled by selecting different nozzle diameters D and formed angle of deposited droplet θ. According to the experiment results, a micro thin-walled structure with wall thickness of 400 μm was fabricated by adjusting the process parameters. The above research works show that it is feasible to fabricate the micro thin-walled metal parts by micro-droplet deposition manufacturing technique.     

Modelling the shape and thermal dynamics of Ni superalloy rings during spray forming Part 1: Shape modelling – Droplet deposition,splashing and redeposition

A numerical model has been developed to simulate the dynamic shape evolution of Ni superalloy rings during spray forming. The model comprises: (1) a droplet primary deposition model, simulating droplet primary deposition at a deposition surface; (2) a droplet splashing model, simulating the droplet splashing/scattering behaviour; and (3) a droplet redeposition model, simulating the redeposition of the scattered droplets onto the deposition surface. The model has been validated against experiments of spray forming large diameter IN718 alloy rings, and for the first time, the effects of droplet splashing and redeposition on the dynamic shape evolution of spray forming IN718 alloy rings and the deposition yields have been investigated and quantified. The model serves as the basis for a thermal dynamic model that is described in Part 2 of this publication.     

Development of a welding system for 3D steel rapid prototyping process

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超疏水材料表面冷凝液滴自移除及液滴尺寸分布规律

目的优化电化学沉积法制备氢氧化铜纳米结构的实验参数,探究不同润湿性表面冷凝液滴尺寸分布规律。方法采用正交试验法,综合考虑电解液浓度、反应温度、极化时间、电流密度对接触角的影响,并通过SEM分析其表面形貌。同时,基于MATLAB软件,提出一种能快速精确识别、提取并统计冷凝液滴特征值的图像处理方法。结果正交试验最优参数为浓度0.5mol/L、温度5℃、时间2000s、电流密度4 mA/cm^2,此时样品表面接触角高达168.8°,滚动角小于3°。冷凝实验结果显示,在超疏水表面,冷凝液滴会频繁的合并自移除,液滴平均粒径最小,粒径在1~10μm范围内的液滴占比维持在50%左右;而在疏水与亲水样表面,冷凝液滴仅能发生合并现象,液滴平均粒径显著增大;冷凝后期,超疏水、疏水与亲水样表面冷凝液滴密度分别稳定在2000、1000、360 mm-2左右。结论纳米针结构能最大限度地降低固液接触面积,降低冷凝液滴粘附力,提高冷凝液滴合并自移除频率,减少冷凝液滴直径,提高冷凝液滴更新率,有望实现高效冷凝传热。同时通过与Image-J图像处理结果比对,验证了该冷凝液滴尺寸分布图像处理方法的可行性。