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This paper aims to investigate the relationship between in situ monitoring characteristics and surface defects in laser-based directed energydeposited Ti-6Al-4V.

In situ monitoring was conducted to extract and quantify the monitoring characteristics of each frame. A two-dimensional contour map was generated using the quantified characteristics to determine the defect formation locations. Computational thermal-fluid dynamics software was used to determine which surface tension terms or shielding gas had a significant effect on the depression of the molten pool.

This study has made a significant contribution by revealing the direct correlation between the molten pool size and brightness with defect formation in laser-based DED of Ti-6Al-4V. It was found that in regions of reduced height, the molten pool exhibited increased size and brightness, leading to surface depressions due to vapor recoil pressure flattening the molten pool. Moreover, the results highlighted that the enhanced Marangoni forces, caused by a high-temperature gradient, hindered the proper accumulation of molten metal, exacerbating height reductions. This insight provides a deeper understanding of how molten pool dynamics directly influence surface quality, which is a critical factor in DED processes.

This study contributes to understanding of the relationship between in situ monitoring characteristics and surface defects in laser-based directed energy-deposited Ti-6Al-4V. Additionally, by using in situ monitoring and computational analysis, significant insights were gained into the factors influencing molten pool behavior and subsequent surface defects.

The purpose of this paper is to study the complex aerosol dynamic processes by using this newly developed stochastically weighted operator splitting Monte Carlo (SWOSMC) method.

Stochastically weighted particle method and operator splitting method are coupled to formulate the SWOSMC method for the numerical simulation of particle-fluid systems undergoing the complex simultaneous processes.

This SWOSMC method is first validated by comparing its numerical simulation results of constant rate coagulation and linear rate condensation with the corresponding analytical solutions. Coagulation and nucleation cases are further studied whose results are compared with the sectional method in excellent agreement. This SWOSMC method has also demonstrated its high numerical simulation capability when used to deal with simultaneous aerosol dynamic processes including coagulation, nucleation and condensation.

There always exists conflict and tradeoffs between computational cost and accuracy for Monte Carlo-based methods for the numerical simulation of aerosol dynamics. The operator splitting method has been widely used in solving complex partial differential equations, while the stochastic-weighted particle method has been commonly used in numerical simulation of aerosol dynamics. However, the integration of these two methods has not been well investigated.

This paper aims to investigate the thermal fluid–structure interactions (FSIs) of printed circuit boards (PCBs) at different component configurations during the wave soldering process and experimental validation.

The thermally induced displacement and stress on the PCB and its components are the foci of this study. Finite volume solver FLUENT and finite element solver ABAQUS, coupled with a mesh-based parallel code coupling interface, were utilized to perform the analysis. A sound card PCB (138 × 85 × 1.5 mm3), consisting of a transistor, diode, capacitor, connector and integrated circuit package, was built and meshed by using computational fluid dynamics pre-processing software. The volume of fluid technique with the second-order upwind scheme was applied to track the molten solder. C language was utilized to write the user-defined functions of the thermal profile. The structural solver analyzed the temperature distribution, displacement and stress of the PCB and its components. The predicted temperature was validated by the experimental results.

Different PCB component configurations resulted in different temperature distributions, thermally induced stresses and displacements to the PCB and its components. Results show that PCB component configurations significantly influence the PCB and yield unfavorable deformation and stress.

This study provides PCB designers with a profound understanding of the thermal FSI phenomenon of the process control during wave soldering in the microelectronics industry.

This study provides useful guidelines and references by extending the understanding on the thermal FSI behavior of molten solder for PCBs. This study also explores the behaviors and influences of PCB components at different configurations during the wave soldering process.

Thermal failure and incomplete separation often occur in aviation wet friction clutches. The purpose of this study is to improve the performance and reliability of the clutch, considering the influence of lubricating oil, in this paper, the finite element method is used to simulate the friction pair of clutch with separation spring.

Considering the influence of lubricating oil, based on computational fluid dynamics principle and applying multiple reference frame method, simulation is carried out in FLUENT software to study the distribution of flow field and temperature field of clutch friction pair and separation spring under the condition of maximum relative speed of 3000 r/min.

The middle friction pair has more oil distribution, while the two sides have less oil distribution, and the highest oil volume exceeds that of the lowest by a factor of 3.49. Under the influence of lubricating oil distribution and component heat conduction, the temperature of the separation spring on both sides is higher than that of the separation spring in the middle. The axial temperature distribution law of the friction pair is the same as that of the separation spring, and the difference of the highest temperature between the friction pair is 136.41°C.

The heat generation of the clutch is studied to improve the performance of the clutch and ensure the safety of the helicopter.

By analyzing the temperature and flow field of a wet friction clutch with a separation spring, engineers can help provide the service life and reliability of the clutch friction pair.

The aim of this study is to investigate the effects of offset angle in wave soldering by using thermal fluid structure interaction modeling with experimental validation.

The authors used a thermal coupling approach that adopted mesh-based parallel code coupling interface between finite volume-and finite element-based software (ABAQUS). A 3D single pin-through-hole (PTH) connector with five offset angles (0 to 20°) on a printed circuit board (PCB) was built and meshed by using computational fluid dynamics preprocessing software called GAMBIT. An implicit volume of fluid technique with a second-order upwind scheme was also applied to track the flow front of solder material (Sn63Pb37) when passing through the solder pot during wave soldering. The structural solver and ABAQUS analyzed the temperature distribution, displacement and von Mises stress of the PTH connector. The predicted results were validated by the experimental solder profile.

The simulation revealed that the PTH offset angle had a significant effect on the filling of molten solder through the PCB. The 0° angle yielded the best filling profile, filling time, lowest displacement and thermal stress. The simulation result was similar to the experimental result.

This study provides a better understanding of the process control in wave soldering for PCB assembly.

This study provides fundamental guidelines and references for the thermal coupling method to address reliability issues during wave soldering. It also enhances understanding of capillary flow and PTH joint issues to achieve high reliability in PCB assembly industries.

Additive manufacturing (AM) is revolutionizing the manufacturing industry due to several advantages and capabilities, including use of rapid prototyping, fabrication of complex geometries, reduction of product development cycles and minimization of material waste. As metal AM becomes increasingly popular for aerospace and defense original equipment manufacturers (OEMs), a major barrier that remains is rapid qualification of components. Several potential defects (such as porosity, residual stress and microstructural inhomogeneity) occur during layer-by-layer processing. Current methods to qualify AM parts heavily rely on experimental testing, which is economically inefficient and technically insufficient to comprehensively evaluate components. Approaches for high fidelity qualification of AM parts are necessary.

This review summarizes the existing powder-based fusion computational models and their feasibility in AM processes through discrete aspects, including process and microstructure modeling.

Current progresses and challenges in high fidelity modeling of AM processes are presented.

Potential opportunities are discussed toward high-level assurance of AM component quality through a comprehensive computational tool.

This study aims to investigate the temperature rise characteristics of vibrating rolling bearings under the influence of the polarization force of unbalanced eccentric blocks. A thermal-fluid-solid mechanics coupled finite element model is established to analyze the effects of different loads and rotational speeds on bearing temperature to prevent overheating, wear and thermal damage.

A thermal-fluid-solid mechanics coupled finite element model of the vibrating rolling bearing is developed based on the principles of heat transfer. Finite element analysis software is used to conduct numerical simulations and study the temperature distribution of the bearing system under different loads and speeds. The model’s accuracy is verified by experimentally measuring the actual temperature of the bearing under the same working conditions.

This study successfully established a thermal-fluid-solid mechanics coupled finite element model of a vibrating rolling bearing, verifying its accuracy and reliability. The research results provide an essential reference for optimizing bearing design, preventing overheating and extending service life.

By analyzing the temperature rise characteristics under various load and rotational speed conditions, the law governing the internal temperature distribution of bearings is revealed. This finding offers a theoretical foundation for comprehending the thermal behavior of bearings.

This study offers a scientific foundation for the maintenance and fault diagnosis of shaker rolling bearings, aiding in the timely identification and resolution of thermal damage issues. Through the optimization of bearing design and usage conditions, the equipment’s lifespan can be prolonged, maintenance expenses can be minimized and production efficiency can be enhanced.

A thermal-fluid-solid mechanics coupled finite element model of a vibrating rolling bearing was established, considering the interaction of multiple physical fields. The influence of the polarization force from the unbalanced eccentric block on the bearing temperature is analyzed in detail, which is close to the actual working conditions.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2024-0396/

This study aims to research the erosion wear characteristics and sealing performance of V-regulating ball valve in coal chemical process pipelines, which provides a theoretical reference for improving its antiwear and sealing performance.

Taking the V-regulating ball valve as the research object, based on the computational fluid dynamics and the theory of erosion wear, the authors studied its erosion characteristics under different medium parameters and analyzed the sealing performance under the heat-fluid–solid coupling working condition.

The erosion wear mechanism of the valve sealing surface is the simultaneous action of cutting and deformation. When the medium flow velocity, particle mass flow rate and particle size increase, the maximum erosion rate and average erosion rate in the V-regulating valve increase. The inner diameter Mises contact stress of the sealing surface is symmetrically distributed in a “wing shape,” and the contact stress of the outer diameter is distributed in a “butterfly shape.” Due to the superposition of thermal stress and pressure stress in the contact transition zone to produce a significant stress concentration.

The findings will provide a theoretical basis for improving the erosion resistance and sealing performance of V-regulating ball valve in coal chemical industry.

V-type regulating ball valve is widely favored by coal chemical enterprises and petrochemical enterprises because of its wide adjustment ratio and good erosion resistance.

The V-regulating ball valve wear mechanism for cutting and deformation simultaneously, and its wear rate is positively correlated with the medium flow rate, particle mass flow rate and particle size. After the valve is opened, there is a significant stress concentration occurs in the contact transition zone due to the superposition of thermal stress and compressive stress. The findings will provide a theoretical basis for improving the erosion resistance and sealing performance of V-regulating ball valve in coal chemical industry.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2024-0205/

The purpose of this study is to carry out a comprehensive analysis of magneto-hydrodynamics (MHD), nanofluidic flow dynamics and heat transfer as well as thermodynamic irreversibility, within a novel butterfly-shaped cavity. Gaining a thorough understanding of these phenomena will help to facilitate the design and optimization of thermal systems with complex geometries under magnetic fields in diverse applications.

To achieve the objective, the finite element method is used to solve the governing equations of the problem. The effects of various controlling parameters such as butterfly-shaped triangle vertex angle (T), Rayleigh number (Ra), Hartmann number (Ha) and magnetic field inclination angle (γ ) on the hydrothermal performance are analyzed meticulously. By investigating the effects of these parameters, the authors contribute to the existing knowledge by shedding light on their influence on heat and fluid transport within butterfly-shaped cavities.

The major findings of this study reveal that the geometrical shape significantly alters fluid motion, heat transfer and irreversibility production. Maximum heat transfer, as well as entropy generation, occurs when the Rayleigh number reaches its maximum, the Hartmann number is minimized and the angle of the magnetic field is set to 30° or 150°, while the butterfly wings angle or vertex angle is kept at a maximum of 120°. The intensity of the magnetic field significantly controls the heat flow dynamics, with higher magnetic field strength causing a reduction in the flow strength as well as heat transfer. This configuration optimizes the heat transfer characteristics in the system.

Further research can be expanded on this study by examining thermal performance under different curvature effects, orientations, boundary conditions and additional factors. This can be accomplished through numerical simulations or experimental investigations under various multiphysical scenarios.

The geometric configurations explored in this research have practical applications in various engineering fields, including heat exchangers, crystallization processes, microelectronic devices, energy storage systems, mixing processes, food processing, air-conditioning, filtration and more.

This study brings value by exploring a novel geometric configuration comprising the nanofluidic flow, and MHD effect, providing insights and potential innovations in the field of thermal fluid dynamics. The findings contribute a lot toward maximizing thermal performance in diverse fields of applications. The comparison of different hydrothermal behavior and thermodynamic entropy production under the varying geometric configuration adds novelty to this study.

This study aims to investigate the effects of thermal buoyancy and flow incidence angles on mixed convection heat transfer and vortex-induced vibration (VIV) of an elastically mounted circular cylinder. The focus is on understanding how varying these parameters influences the vibration amplitudes in both the x and y directions and the overall heat transfer performance.

The research involves a numerical simulation of thermal fluid-structure interactions by integrating rigid-body motion equations with heat and fluid flow solvers. The cylinder operates at a lower temperature than the mainstream flow, and flow incidence angles range from 0° (opposing gravity) to 90° (perpendicular to gravity). The methodology is validated by comparing the results with established data on VIV for a cylinder vibrating in one direction under thermal buoyancy effects.

The study reveals that, without buoyancy (Ri = 0), increasing the flow angle from 0° to 90° decreases the vibration amplitude along the x-direction (A_x) while increasing it along the y-direction (A_y) across various reduced velocities (U_r). When buoyancy effects are introduced (Ri = −1), A_x peaks at specific U_r values depending on the flow angle, with significant variations observed. The maximum increase in A_x at Ri = −1 is over 15 times at U_r = 9 for a 0° angle, and A_y shows a more than 10-fold increase at U_r = 8 for a 30° angle. Additionally, adjusting the flow angle results in up to an 8% increase in the mean Nusselt number at Ri = −1.

This research provides novel insights into the combined effects of flow incidence angles and thermal buoyancy on VIV and heat transfer in an elastically mounted cylinder.