Modelling of Bond Formation during Overprinting of PEEK Laminates.

The rapid technological progress of large-scale CNC (computer numerical control) systems for Screw Extrusion Additive Manufacturing (SEAM) has made the overprinting of composite laminates a much-discussed topic. It offers the potential to efficiently produce functionalised high-performance structures. However, bonding the 3D-printed structure to the laminate has proven to be a critical point. In particular, the bonding mechanisms must be precisely understood and controlled to ensure in situ bonding. This work investigates the applicability of healing models from 3D printing to the overprinting of thermoplastic laminates using semi-crystalline, high-performance material like PEEK (polyether ether ketone). For this purpose, a simulation methodology for predicting the bonding behaviour is developed and tested using experimental data from a previous study. The simulation consists of a transient heat analysis and a diffusion healing model. Using this model, a qualitative prediction of the bond strength could be made by considering the influence of wetting. It was shown that the thermal history of the interface and, in particular, the tolerance of the deposition of the first layer are decisive for in situ bonding. The results show basic requirements for future process and component developments and should further advance the maturation of overprinting.

Machine learning method predicting thermal performance of conformal cooling systems.

The incorporation of conformal cooling systems has significantly enhanced the efficiency and quality of injection molding process. While several automated methods have been developed for creating conformal cooling channels in injection molds, the current optimization process for conformal cooling design parameters is hindered by labor-intensive iterative thermal simulation processes and the substantial reliance on empirical human knowledge. This paper presents an innovative machine learning method to assess the thermal performance of conformal cooling systems by employing a combination of a non-linear regression model and a neural network. By employing a logarithmic regression model describing the temperature graph and a neural network predicting the coefficients of the logarithmic regression model, the thermal performance of specified conformal cooling systems can be assessed and predicted precisely. This methodology empowers designers to evaluate the thermal efficiency of conformal cooling systems efficiently and effectively to further optimize the conformal cooling design parameters without relying on tedious manual thermal and fluid simulation processes.

Research on Improved Crystallization Properties and Underlying Mechanism of the Sb2Te3 Phase-Change Thin Film by Inserting Sn15Sb85 Layers.

As a non-volatile semiconductor memory technology, phase-change memory has a wide range of application prospects as a result of the excellent comprehensive performance. In this paper, multilayer thin films based on Sb2Te3 material were designed and prepared by inserting the Sn15Sb85 layer. The thermal and electrical properties of superlattice-like Sb2Te3/Sn15Sb85 phase-change films can be adjusted by controlling the thickness ratio of Sb2Te3/Sn15Sb85. In comparison to the monolayer Sb2Te3 film, the multilayer layer Sb2Te3/Sn15Sb85 materials have a higher crystallization temperature, larger crystallization activation energy, and longer data lifetime, indicating the great improvement of thermal stability. The changes in the phase structure and vibrational modes of multilayer Sb2Te3/Sn15Sb85 films were characterized by X-ray diffraction and Raman spectroscopy, respectively. The presence of Sn15Sb85 layers restrains grain growth and refines the grain size. The multilayer Sb2Te3/Sn15Sb85 films exhibit better surface flatness, smaller surface potential undulation, and lower thickness variations than single-layer Sb2Te3. Phase-change memory cells based on the [Sb2Te3 (1 nm)/Sn15Sb85 (9 nm)]5 thin film has a lower threshold voltage (1.9 V) and threshold current (3.1 µA) compared to the Ge2Sb2Te5 film. Meanwhile, the electrical heating model of a phase-change memory cell based on a [Sb2Te3 (1 nm)/Sn15Sb85 (9 nm)]5 multilayer structure was established by multiphysics coupling analysis, proving the great improvement in heat transfer performance and efficiency. The experimental and theoretical studies confirm that the insertion of the Sn15Sb85 layer can significantly improve the crystallization properties of Sb2Te3 films, paving the way for optimizing the phase-change materials by regulating the microstructural parameters.

Comparative Analysis of Meteorological versus In Situ Variables in Ship Thermal Simulations.

Thermal simulations have become increasingly popular in assessing energy efficiency and predicting thermal behaviors in various structures. Calibration of these simulations is essential for accurate predictions. A crucial aspect of this calibration involves investigating the influence of meteorological variables. This study aims to explore the impact of meteorological variables on thermal simulations, particularly focusing on ships. Using TRNSYS (TRaNsient System Simulation) software (v17), renowned for its capability to model complex energy systems within buildings, the significance of incorporating meteorological data into thermal simulations was analyzed. The investigation centered on a patrol vessel stationed in a port in Galicia, northwest Spain. To ensure accuracy, we not only utilized the vessel's dimensions but also conducted in situ temperature measurements onboard. Furthermore, a dedicated weather station was installed to capture real-time meteorological data. Data from multiple sources, including Meteonorm and MeteoGalicia, were collected for comparative analysis. By juxtaposing simulations based on meteorological variables against those relying solely on in situ measurements, we sought to discern the relative merits of each approach in enhancing the fidelity of thermal simulations.

Simulation on an Advanced Double-Sided Cooling Flip-Chip Packaging with Diamond Material for Gallium Oxide Devices.

Gallium oxide (Ga2O3) devices have shown remarkable potential for high-voltage, high-power, and low-loss power applications. However, thermal management of packaging for Ga2O3 devices becomes challenging due to the significant self-heating effect. In this paper, an advanced double-sided cooling flip-chip packaging structure for Ga2O3 devices was proposed and the overall packaging of Ga2O3 chips was researched by simulation in detail. The advanced double-sided cooling flip-chip packaging structure was formed by adding a layer of diamond material on top of the device based on the single-sided flip-chip structure. With a power density of 3.2 W/mm, it was observed that the maximum temperature of the Ga2O3 chip with the advanced double-sided cooling flip-chip packaging structure was 103 °C. Compared with traditional wire bonding packaging and single-sided cooling flip-chip packaging, the maximum temperature was reduced by about 12 °C and 7 °C, respectively. When the maximum temperature of the chip was controlled at 200 °C, the Ga2O3 chip with double-sided cooling packaging could reach a power density of 6.8 W/mm. Finally, by equipping the top of the package with additional water-cooling equipment, the maximum temperature was reduced to 186 °C. These findings highlight the effectiveness of the proposed flip-chip design with double-sided cooling in enhancing the heat dissipation capability of Ga2O3 chips, suggesting promising prospects for this advanced packaging structure.

Nanosecond multipulse retinal damage thresholds of elongated irradiance profiles in explant measurements and simulations.

Significance: The database for multipulse retinal damage thresholds for the laser safety standard (IEC 60825-1:2014) is confined, especially for elongated irradiation profiles. To ensure eye safety, retinal damage thresholds (ED50 values) need to be determined. Aim: This study aims to examine nanosecond multipulse scenarios. Approach: To determine ED50 values in ex vivo measurements, an optical laser setup is presented. Porcine explant tissue is irradiated with rectangular top-hat profiles. Thermal simulations are carried out on a validated computer model and retinal injury thresholds are obtained. Results: The measurements resulted in ED50 values from 8.46 to 42.72 µJ with a slope from 1.15 to 1.4. A thermal damage in the measurements can be excluded due to the level value in combination with a different type of declining behavior for increasing pulses compared to the simulations. A dependence with increasing elongation or area of the retinal image emerges in the simulations but could not be confirmed in the measurements due to the influencing factors (biological variability, focusing, and measuring procedure). Conclusions: Using slit apertures for beam shaping, variable rectangular spot geometries are realized without changing elements in the setup. For further evaluation of the behavior of elongated irradiation profiles, additional measurements to improve the measurement accuracy are necessary.

Effect of Nb Content and Second Heat Cycle Peak Temperatures on Toughness of X80 Pipeline Steel.

The microstructure evolution and variation of impact toughness in the heat-affected zone (HAZ) of X80 pipeline steel with different Nb content under different peak temperatures in the secondary thermal cycle were studied through welding thermal simulation, the Charpy impact test, EBSD analysis, SEM observation, and TEM observation in this study. The results indicate that when the peak temperatures of the second pass were lower than Ac1, both X80 pipeline steels had high impact toughness. For secondary peak temperatures in the range of Ac1 to Ac3, both X80 pipeline steels had the worst impact toughness, mainly due to the formation of massive blocky M-A constituents in chain form on grain boundaries. When the secondary peak temperatures were higher than Ac3, both X80 pipeline steels had excellent impact toughness. Smaller grain size and higher proportions of HAGBs can effectively improve the impact toughness. Meanwhile, high Nb X80 pipeline steel had higher impact absorption energy and smaller dispersion. Adding an appropriate amount of Nb to X80 pipeline steel can ensure the impact toughness of SCCGHAZ and SCGHAZ in welded joints.

Failure Analysis of Cracked P110 Repaired Tubing Used for Gas Transmission.

With green and low-carbon developments in oil fields, an increasing amount of repaired oil tubing is being used as oil and gas transmission pipelines in China. However, due to differences in manufacturing standards between oil tubing and transmission pipelines, there are inevitably some issues during their use. This paper investigates a case of cracking failure in repaired oil tubing used as a gathering and transportation pipeline. The failure occurred after eight months of operation and was characterized by a circumferential crack at the male thread end of the tubing joint. To determine the root cause of the failure, a series of experiments were conducted on the oil tubing. The experiments included visual inspection, chemical composition analysis, mechanical properties testing, hardness testing, metallographic examination, and microstructure analysis. The results revealed that the thread of the cracked tubing was not tightened to the specified position; the connection between the tubing and the coupling was welded in a circumferential direction; and cracks occurred in the heat-affected zone of the weld. Chemical composition, tensile performance, and the Charpy impact of the tubing meet the requirements of API 5CT for P110 material, and no abnormalities were found in the metallographic structure. The microstructure at the weld toe of the fracture is martensite, and the hardness is 476 HV10. Based on the thermal simulation verification test, when the material of the tubing cools from 1200 °C, which is located in the coarse HAZ temperature zone, the base metal transforms into martensite with a little granular bainite, exhibiting its highest hardness value at 371 HV10, which is higher than the allowable hardness for carbon steel and indicates the material has poor weldability. The reasons for the cracking and failure of the tubing are that the P110 repaired tubing has a high carbon equivalent and poor weldability. During the welding process, martensitic structure was formed at the weld toe, and cold cracks appeared in the heat-affected zone, resulting in failure. To avoid the reoccurrence of such failure, recommendations are proposed.

Drilling Sequence Optimization Using Evolutionary Algorithms to Reduce Heat Accumulation for Femtosecond Laser Drilling with Multi-Spot Beam Profiles.

We report on laser drilling borehole arrays using ultrashort pulsed lasers with a particular focus on reducing the inadvertent heat accumulation across the workpiece by optimizing the drilling sequence. For the optimization, evolutionary algorithms are used and their results are verified by thermal simulation using Comsol and experimentally evaluated using a thermal imaging camera. To enhance process efficiency in terms of boreholes drilled per second, multi-spot approaches are employed using a spatial light modulator. However, as higher temperatures occur across the workpiece when using simultaneous multi-spot drilling as compared to a single-spot process, a subtle spatial distribution and sequence of the multi-spot approach has to be selected in order to limit the resulting local heat input over the processing time. Different optimization approaches based on evolutionary algorithms aid to select those drilling sequences which allow for the combination of a high efficiency of multi-spot profiles, a low-generated process temperature and a high-component quality. In particular, using a 4 × 4 laser spot array allows for the drilling of 40,000 boreholes in less than 76 s (526 boreholes/s) with a reduced temperature increase by about 35%, as compared to a single spot process when employing an optimized drilling sequence.

Inter-Critically Reheated CGHAZ of Ultra-High-Strength Martensitic Steel with Different Cooling Rates.

The mechanical properties of steel's inter-critically reheated coarse-grained heat-affected zone (ICR CGHAZ) directly affects the service life of machinery equipment. The hardness and toughness of ICR CGHAZ can be optimized simultaneously through tailoring microstructure where cooling rate plays a key role. In this work, the samples with different cooling rates was prepared using thermal simulation. The granite bainite (GB), bainite ferrite (BF) and MA were formed at a 1 °C/s (CR1) cooling rate, while BF and MA were formed at 10 °C/s (CR2) and 30 °C/s (CR3) cooling rates. With the increase of cooling rate, the effective grain size decreased and the number of hard phases increased, resulting in monotonic increase of hardness (260HV3, 298HV3 and 323HV3). CR1 had sparsely distributed coarse slender MA and CR3 possessed tail-head connected MA along PAGBs, which was detrimental to toughness. Therefore, CR2 possessed the best toughness(25J). The microstructural evolution mechanism of ICR CGHAZ with different cooling rates is investigated, corresponding hardening and toughening mechanisms are discussed.

A novel electron source for a compact x-ray tube for microbeam radiotherapy with very high dose rates.

Microbeam radiotherapy (MRT) is a novel concept in radiation oncology with arrays of alternating micrometer-wide high-dose peaks and low-dose valleys. Preclinical experiments have shown a lower normal tissue toxicity for MRT with similar tumor control rates compared to conventional radiotherapy. A promising candidate for the demanded compact radiation source is the line-focus x-ray tube. Here, we present the setup of a prototype for an electron accelerator being able to provide a suitable x-ray beam for the tube. Several beam dynamic calculations and simulations were performed concerning particle tracking, thermal and electrostatic properties of the electron source, resulting in a proper beamline, including the cathode, the pierce electrode (PE) and the focusing magnets. These parts are discussed separately. The simulations showed that a rectangular cathode with a small width of 0.4mm is mandatory. To quickly shut down the electron beam, an additional voltage of -600V must be applied to the PE. Moreover, the electric field inside the vacuum chamber stays below 10MVm-1 to minimize the risk of field emission. The thermal simulation validates a small displacement of 0.1mm of the heated cathode with respect to the PE, which must be considered during manufacturing of the cathode-PE assembly. The simulations lead to an adequate choice of cathode, electrodes and beamline to achieve the required focal spot of 0.05×20mm2 with a beam current of 0.3A and an electron energy of 300keV. With this setup first MRT experiments with high dose rates up to 10Gys-1 can be executed.

Roasting mechanism of lightweight low-aluminum-silicon ceramisite derived from municipal solid waste incineration fly ash and electrolytic manganese residue.

Municipal solid waste incineration (MSWI) fly ash and electrolytic manganese residue (EMR) belong to hazardous waste, and must be disposed of before processing. It was found that the low content of silicon and aluminum at low roasting temperature can meet the expansion mechanism of lightweight aggregates. A low-aluminum-silicon lightweight ceramisite was successfully prepared from MSWI fly and EMR, the formation mechanism of which was that the viscosity of molten stuffs in pellet was the function of temperature and chemical composition and had enough capacity of capturing the emerged gas over roasting. The resulting ceramisite met with the requirement of Lytag commercial lightweight aggregate. The content of heavy metal in ceramisite accorded with the requirement of soil environmental quality for development GB 36600-2018 Class I, and PCDD/Fs in ceramisite was 2.0 ng I-TEQ/kg, which was safe. The collaboration of thermal simulation and characterization (SEM-EDS, FTIR and XRD) elaborated the formation mechanism of ceramisite, with six stages provided.

Optimization of Heat Accumulation during Femtosecond Laser Drilling Borehole Matrices by Using a Simplex Algorithm.

We report on an optimization study of percussion drilling thin metal sheets employing a high repetition rate, high power femtosecond laser with respect to the resulting heat accumulation. A specified simplex algorithm was employed to optimize the spatial drilling sequence, whereas a simplified thermal simulation using COMSOL was validated by comparing its results to the temperature measurements using an infrared camera. Optimization for drilling borehole matrices was aspired with respect to the generated temperature across the processed specimen, while the drilling strategy was altered in its spatial drilling sequence and by using multi-spot approaches generated by a spatial light modulator. As a result, we found that an optimization strategy based on limited consecutive holes in a Moore neighborhood led to reduced temperatures and the shortest process times.

Effect of Nb Addition and Heat Input on Heat-Affected Zone Softening in High-Strength Low-Alloy Steel.

The effect of both Nb content and heat input on the softening phenomenon of the heat-affected zone (HAZ) of low-alloy high-strength steel was studied through welding thermal simulation experiments. The microstructure evolution, density variation of geometrically necessary dislocation, microhardness distribution and the second phase precipitation behavior in HAZ was characterized and analyzed by combining the optical microscope, scanning electron microscope, high-resolution transmission electron microscope with microhardness tests. The results showed that the softening appeared in the fine-grain HAZ (FGHAZ) of the low-alloy high-strength steel with the polygonal ferrite and bainite microstructure. With an increase in Nb content, the FGHAZ softening was inhibited even with high heat input; however, the hardness shows little variation. On the one hand, the increase in the Nb content increased the volume fraction of high-strength bainite in the FGHAZ. On the other hand, the remarkable strengthening was produced by the equally distributed precipitation nanoparticles. As a result, the two factors were the main reason for the solution of the FGHAZ softening problem in the low-alloyed high-strength steel with the mixed microstructure of ferrite and bainite.

Evaluation of specific absorption rate and heating in children exposed to a 7T MRI head coil.

PURPOSE: To evaluate specific absorption rate (SAR) and temperature distributions resulting from pediatric exposure to a 7T head coil. METHODS: Exposure from a 297-MHz birdcage head transmit coil (CP mode single-channel transmission) was simulated in several child models (ages 3-14, mass 13.9-50.4 kg) and one adult, using time-domain electromagnetic and thermal solvers. Position variability, age-related changes in dielectric properties, and differences in thermoregulation were also considered. RESULTS: Age-adjusted dielectric properties had little effect in this population. Head average SAR (hdSAR) was the limiting factor for all models centered in the coil. The value of hdSAR (normalized to net power) was found to decrease linearly with increasing mass (R2  = 0.86); no equivalent relationship for peak-spatial 10g averaged SAR (psSAR10g ) was identified. Relatively small (< 10%) variability was observed in hdSAR for position shifts of ±25 mm in each orthogonal direction when normalized to net power; accounting for B1+$$ {\mathrm{B}}_1^{+} $$ efficiency can lead to much larger variability. Position sensitivity of psSAR10g was greater, but in most cases hdSAR remained the limiting quantity. For thermal simulations, if blood temperature is fixed (i.e., asserting good thermoregulation), maximum temperatures are compliant with International Electrotechnical Commission limits during 60-min exposure at the SAR limit. Introducing variable blood temperature leads to core temperature changes proportional to whole-body averaged SAR, exceeding guideline limits for all child models. CONCLUSIONS: Children experienced higher SAR than adults for the 297-MHz head transmit coil examined in this work. Thermal simulations suggest that core temperature changes could occur in smaller subjects, although experimental data are needed for validation.

Large-Scale Robot-Based Polymer and Composite Additive Manufacturing: Failure Modes and Thermal Simulation.

Additive manufacturing (AM) of large-scale polymer and composite parts using robotic arms integrated with extruders has received significant attention in recent years. Despite the contributions of great technical progress and material development towards optimizing this manufacturing method, different failure modes observed in the final printed products have hindered its application in producing large engineering structures used in aerospace and automotive industries. We report failure modes in a variety of printed polymer and composite parts, including fuel tanks and car bumpers. Delamination and warpage observed in these parts originate mostly from thermal gradients and residual stresses accumulated during material deposition and cooling. Because printing large structures requires expensive resources, process simulation to recognize the possible failure modes can significantly lower the manufacturing cost. In this regard, accurate prediction of temperature distribution using thermal simulations is the first step. Finite element analysis (FEA) was used for process simulation of large-scale robotic AM. The important steps of the simulation are presented, and the challenges related to the modeling are recognized and discussed in detail. The numerical results showed reasonable agreement with the temperature data measured by an infrared camera. While in small-scale extrusion AM, the cooling time to the glassy state is less than 1 s, in large-scale AM, the cooling time is around two orders of magnitudes longer.

Effect of Thermal Simulation Process on Microstructure of Seismic Steel Bars.

Thermal deformation has a significant influence on the microstructure of high-strength antiseismic steel. The effect of hot deformation on the microstructure of experimental steel was studied by the Gleeble-3800 thermal simulator. The microstructure of the steel was characterized by the metallographic microscope, microhardness, tensile test, field emission scanning electron microscope, electron backscatter diffraction, and high-resolution transmission electron microscope. The results show that the core microstructure of the test steel is composed of polygonal ferrite and lamellar pearlite. The test steel is mainly ductile fracture. Tensile strength and hardness increase with the decrease of temperature. At 650 °C isothermal temperature, the ferrite distribution was uniform, the average grain size was 7.78 µm, the grain size grade reached 11, the pearlite lamellar spacing was 0.208 µm, and the tensile fracture was distributed with uniform equiaxed dimples. Polygonal ferrite grain boundaries have high density dislocations that can effectively block the initiation and propagation of cracks. However, there are some low dislocation boundaries and subgrain boundaries in ferrite grains. Precipitation strengthening is mainly provided by fine precipitates of V-rich carbonitride in experimental steel. The precipitates are round or narrow strips, about 70-100 nm in size, distributed along ferrite grain boundaries and matrix.

Simulation and Optimization of a Planar-Type Micro-Hotplate with Si3N4-SiO2 Transverse Composite Dielectric Layer and Annular Heater.

Micro-hotplates (MHPs) have become widely used basic structures in many micro sensors and actuators. Based on the analysis of the general heat transfer model, we propose a new MHP design based on a transversal composite dielectric layer, consisting of different heat transfer materials. Two general proven materials with different thermal conductivity, Si3N4 and SiO2, are chosen to form the composite dielectric layer. An annular heater is designed with a plurality of concentric rings connected with each other. The relationship between MHP performance and its geometrical parameters, including temperature distribution and uniformity, thermal deformation, and power dissipation, has been fully investigated using COMSOL simulation. The results demonstrate that the new planar MHP of 2 µm thick with a Si3N4-SiO2 composite dielectric layer and annular heater can reach 300 °C at a power of 35.2 mW with a mechanical deformation of 0.132 µm, at a large heating area of about 0.5 mm2. The introduction of the composite dielectric layer effectively reduces the lateral heat conduction loss and alleviates the mechanical deformation of the planar MHP compared with a single SiO2 dielectric layer or Si3N4 dielectric layer.

Effect of V Content and Heat Input on HAZ Softening of Deep-Sea Pipeline Steel.

In this paper, the welding thermal cycle process of deep-sea pipeline steel was investigated by welding thermal simulation. The microstructure evolution, crystallology and second-phase precipitation behavior of the soft zone of the heat-affected zone (HAZ) were characterized and analyzed by combining scanning electron microscopy, electron back-scattered diffraction, transmission electron microscopy and hardness testing. The results show that HAZ softening appeared in the fine-grained zone with a peak temperature of 900-1000 °C for deep-sea pipeline steel, the base metal microstructure of which was the polygonal ferrite and acicular ferrite. Using V microalloying and low welding heat input could effectively decrease the softening of the HAZ fine-grained region, which was achieved by reducing the effective grain size, increasing the proportion of the dislocation substructures, and precipitating the nanoscale second-phase particles.

Variable Offset Computation Space for Automatic Cooling Dimensioning.

The injection mold is one of the most important elements for the part precision of this important mass production process. The thermal mold design is realized by cooling channels around the cavity and poses as a decisive factor for the part quality. Thus, the objective but specific design of the cooling channel layout is crucial for a reproducible part with high-dimensional accuracy in production. Consequently, knowledge-based and automated methods are used to create the optimal heat management in the mold. One of these methods is the inverse thermal mold design, which uses a specific calculation space. The geometric boundary conditions of the optimization algorithm influence the resulting thermal balance within the mold. As the calculation area in the form of an offset around the molded part is one of these boundary conditions, its influence on the optimization result is determined. The thermal optimizations show a dependency on different offset shapes due to the offset thickness and coalescence of concave geometries. An algorithm is developed to generate an offset for this thermal mold design methodology considering the identified influences. Hence, a reproducible and adaptive offset is generated automatically for a complex geometry, and the quality function result improves by 43% in this example.