3D Temperature Field Research Articles

Orthogonal dual-channel single-camera spectral imaging for online measurement of three-dimensional space–time evolution of temperature field in laser melt pool

Current temperature measurement technology in laser manufacturing cannot obtain the internal three-dimensional (3D) temperature distribution of the melt pool. Necessary information for laser-manufacturing process optimization is lacking, including the melt pool depth and depth-to-width ratio. We propose a method for 3D temperature measurement based on orthogonal dual-channel single-camera spectral imaging. The 3D temperature field distribution of the melt pool can be obtained by collecting projected radiation data from two perpendicular angles. Use of a single monochrome camera for spectral imaging at three wavelengths ensures excellent spatial and temporal consistency during measurements. To verify the feasibility of the method, we measured the 3D temperature field in a melt pool of 304 stainless steel irradiated by a Gaussian laser beam (continuous laser, 500 W) with different irradiation times. The results indicate that the temperature field exhibits an approximately axisymmetric distribution on each cross-section at different depths. The temperature is highest in the center and gradually decreases around it. As the depth increases, the high-temperature area (>1730 K) gradually becomes smaller, and the temperature of each cross-section decreases. The maximum temperature, depth, width, and depth-to-width ratio of the melt pool at different times were obtained from the measured 3D temperature distributions. With an irradiation time of 0–80 s, the maximum temperature of the melt pool exhibited three stages: rapid increase (20–2230 K), slow increase (2230–2280 K), and stabilization. The growth of the width and depth of the melt pool indicated a similar process, increasing rapidly at first and gradually slowing. The depth-to-width ratio decreased rapidly at first and gradually stabilized. The proposed method for 3D temperature measurement has potential use in laser manufacturing for process control and quality improvement.

Three-dimensional density measurements of a heated jet using laser-speckle tomographic background-oriented schlieren

Tomographic background-oriented schlieren (TBOS) is a promising optical technique for 3D density field measurement in turbulent flows. Path-integrated information on refractive index gradients is captured by cameras looking through the flow at textured background patterns in the form of apparent displacements of the patterns. A tomographic reconstruction of the three-dimensional refractive index gradients is performed, from which the instantaneous three-dimensional density field is obtained. Most TBOS measurements to date have been limited by large temporal blurring and/or large defocus blurring. Our 15-camera experimental set-up uses a pulsed laser for both illumination and creation of a laser-speckle background pattern. The high-power laser ensures adequate exposures in nanoseconds, so temporal integration is minimised in each measurement. The beam is spread to illuminate a surface that is observed by fifteen cameras that are evenly spaced circumferentially around the flow. Laser speckle patterns are observed by the cameras due to the diffuse reflection and interference of coherent light from roughness on the surface. We develop a methodology for selecting the optimal focal length, focus distance, and lens aperture by considering the compromise between displacement sensitivity, defocus blurring and speckle size. Low temporal- and spatial-blurring 3D temperature field measurements with excellent resolution of turbulent flow features are obtained and good agreement with thermocouple. Classical behaviours of the potential core instability such as vortex rollup and radial ejections are identified. The behaviour of the potential core is examined further, which reveals that the potential core undergoes considerable deformation and fragmentation during the transition to turbulence.

Experimental research on temperature field construction of nuclear waste barrel based on RDTS with improved spatial resolution

In this paper, a 3D temperature field construction method based on Raman Distributed Temperature Sensor (RDTS) with improved spatial resolution is proposed to monitor the side surface temperature of Nuclear Waste Barrel (NWB). This method includes two aspects: the spatial resolution enhancement of RDTS and the signal dimension conversion. Firstly, the spatial resolution improvement method combining Fully-Connected Neural Network (FCNN) and Total Variation Deconvolution (TVD) is used to improve the spatial resolution of RDTS from 1.6 m to 0.4 m. Then, the one-dimensional temperature signal is converted into 2D temperature field by matrix laying method. Finally, by establishing the coordinate system of the NWB, the 2D temperature field can be converted into a 3D one. The experimental results of the simulation device showed that when the circular thermal area with diameter of 0.4 m, 0.6 m and 0.8 m appeared on the side surface of NWB, the temperature accuracy of the temperature field image constructed by this method can reach 80.91 %, 72.09 % and 85.97 % respectively, and the shape was accurate. The method proposed in this paper can accurately present the surface temperature field of NWB and provide technical support for the safe operation of the nuclear waste disposal repository during its life cycle.

Numerical simulation and experiment on morphology control of grooves processed by a picosecond laser on TC11 titanium alloy

The chief aim of this paper is to control groove morphology precisely. In this paper, a 2D temperature field model for ultrafast picosecond laser grooving was set up on the foundation of the two-temperature model coupled with the phase change model. Then, a series of simulations were executed to investigate the influence of laser parameters such as laser power, scanning speed and repetition rate on ultrafast picosecond laser grooving. Finally, a number of experiments were performed to verify the model. The results suggest that the laser power has an obvious influence on the groove width and depth because the heat-affected zone area and single-pulse laser energy increase when the laser power varies from 2 W to 5 W. Obvious impacts of scanning speed on the groove depth and quality are observed in the present simulation due to the variation of overlap between sequential pulses and pulse numbers. The groove width and quality depend on the repetition rate. This is because the increase in the repetition rate has a certain contribution to increasing the temperature of heat residue and pulse number. This research contributes to present theoretical guidance on laser grooving.

Simultaneous measurement of microscale fluid viscosity, temperature, and velocity fields by tracking Janus particle on microparticle image velocimetry

Multifunctional sensing capability enables a comprehensive understanding of the unknown target to be measured. Given that fluid viscosity, temperature, and velocity fields are usually coupled parameters in a system, simultaneous measurement of the three environmental factors can prevent cross-talk and improve reliability. However, the task is apparently challenging because of the microscale targets. A technique combining microparticle image velocimetry and Janus particles was developed in this study to address such demand. With the rotational diffusivity and particle trajectories measured by the proposed technique and an empirical water-based viscosity-temperature relationship, the three unknown variables in a microfluidic environment were solved. The blinking frequency was derived using the Hilbert Huang Transform. Compared with those in a static and uniform temperature field, the measured data had good agreement with the predicted values. However, the agreement was impaired when the heating rate exceeded 0.34 °C/s. The optimal temperature range was found between 10 °C and 40 °C in the water-based solution. For a steady-state and nonuniform temperature field, two-dimensional (2D) numerical simulations of three linear temperature gradients were also studied. Results showed that the deviation increased as the temperature gradient increased or was near the low-temperature region. The same procedure was eventually applied to a real thermophoretic flow induced by an IR laser in a microchip. The 2D fluid viscosity, temperature, and velocity fields in the microchip were successfully obtained by tracking 10 particles. The potential of the approach provides insight into understanding some microfluidic applications with mild changes in temperature or creeping flow. This study combined µPIV with Janus particles to achieve simultaneous measurement of 2D microscale fluid viscosity, temperature, and velocity fields. By simply tracking the particles, particle trajectories and blinking signal were obtained. Both parameters provided sophisticated information of particle velocity and rotational diffusivity. With the information, the viscosity and temperature were hence derived from the empirical viscosity–temperature relationship and the Stokes-Einstein-Debye relation. The velocity was derived alone based on the conventional cross-correlation algorithm. • Using Janus particles as tracers to provide dynamic information of blinking signal and trajectories. • Simultaneous measurement of whole field fluid viscosity, temperature, and velocity at the microscale. • Extraction of the frequency spectrum out of blinking signal by Hilbert Huang Transform. • A measurable temperature range between 10 °C and 40 °C.

Nanoscale thermometry under ambient conditions via scanning thermal microscopy with 3D scanning differential method.

Local temperature measurement with high resolution and accuracy is a key challenge in nowadays science and technologies at nanoscale. Quantitative characterization on temperature with sub-100nm resolution is of significance for understanding the physical mechanisms of phonon transport and energy dissipation in nanoelectronics, optoelectronics, and thermoelectric devices. Scanning thermal microscopy (SThM) has been proved to be a versatile method for nanoscale thermometry. In particular, 2D profiling of the temperature field on the order of 10nm and 10 mK has already been achieved by SThM with modulation techniques in ultrahigh vacuum to exclude the parasitic heat flow between air and the cantilever. However, few attempts have been made to truly realize 2D profiling of temperature quantitatively under ambient conditions, which is more relevant to realistic applications. Here, a 3D scanning differential method is developed to map the 2D temperature field of an operating nanodevice under ambient environment. Our method suppresses the thermal drift and the parasitic heat flow between air and the cantilever by consecutively measuring the temperatures in thermal contact and nonthermal contact scenarios rather than in a double-scan manner. The local 2D temperature field of a self-heating metal line with current crowding by a narrowing channel is mapped quantitatively by a sectional calibration with a statistic null-point method and a pixel-by-pixel correction with iterative calculation. Furthermore, we propose a figure of merit to evaluate the performance of thermocouple probes on temperature field profiling. The development of nanoscale thermometry under ambient environment would facilitate thermal manipulation on nanomaterials and nanodevices under practical conditions.

Space temperature field and structure response of multi-chamber cabin subjected to fire

Ship structures may collapse or suffer serious deformation when subjected to fire. To accurately assess the structure safety of ships undergone fires, based on large eddy simulation of fire dynamics algorithm and the structural thermo-mechanical coupling response method, a thermal-mechanical coupling data interface is established. Taking a multi-chamber cabin as an example, the spatial temperature field of cabin under fire was studied, and the structural temperature load was obtained by using the 3D spatial temperature field data as the boundary. On this basis, the structural response of multi-chamber cabin subjected to fire was investigated, and the prediction model of residual bearing capacity of cabin was proposed. The space temperature of the fire source layer is greatly affected by the ventilation conditions, and the temperature fluctuation at the stair shaft is large due to the chimney effect. The stress and deformation of multi-chamber cabin under ambient temperature and fire are compared to reveal their different damage mechanism. Moreover, the residual bearing capacity of the cabin is positively correlated with the fire power, and the ultimate strength of the cabin within 0–4 MW is predicted.

2D Temperature Field Reconstruction Using Optical Frequency Domain Reflectometry and Machine-Learning Algorithms.

We present experimental results on the reconstruction of the 2D temperature field on the surface of a 250 × 250 mm sensor panel based on the distributed frequency shift measured by an optical backscatter reflectometer. A linear regression and a feed-forward neural network algorithm, trained by varying the temperature field and capturing thermal images of the panel, are used for the reconstruction. In this approach, we do not use any information about the exact trajectory of the fiber, material properties of the sensor panel, and a temperature sensitivity coefficient of the fiber. Mean absolute errors of 0.118 °C and 0.086 °C are achieved in the case of linear regression and feed-forward neural network, respectively.

Electromagnetic‐Thermal Analysis of High‐Temperature Direct Drive Electric‐Actuated Valve Canned Permanent Magnet Synchronous Motor

The high‐temperature electric‐actuated valve widely adopts the split structure, and the valve stem drives the opening and closing of the valve after passing through the high‐temperature packing and sealing structure. However, the transmission chain is too long, which cannot meet the pursuit of small volume and lightweight in the nuclear industry. In this paper, a novel integrated structure of high‐temperature direct drive electric‐actuated valve canned permanent magnet synchronous motor (DDEAV‐CPMSM) is proposed. The structure omits the dynamic sealing structure composed of stuffing box, pressure plate and pressure sleeve, as well as the transmission structure of gears and couplings, and the reliability is significantly improved. This paper focuses on the calculation of the dimension parameters, thermal load design, and electromagnetic vibration of DDEAV‐CPMSM, and compares it with the integrated structure of the induction motor to explore the optimal topology of the high‐temperature electric‐actuated valve. Aiming at the problem of serious heat generation in limited space, it is difficult to simulate the running time of high‐temperature valve. Based on the magneto‐thermal coupling method, a 3D temperature field model considering high‐temperature heat source, canned sleeve eddy current loss, and hydraulic friction loss is established. The steady‐state temperature distribution of the system at high temperature and the transient temperature change law of valve opening and closing are analyzed, and the minimum time of secondary start‐up and the maximum running time under fault conditions are further studied, to provide a theoretical basis for the application of DDEAV‐CPMSM. © 2022 Institute of Electrical Engineers of Japan. Published by Wiley Periodicals LLC.

Research on Vehicle Aerodynamics and Thermal Management Based on 1D and 3D Coupling Simulation

In order to ensure the full heat dissipation of heat exchangers, the opening of the grille should be large, which increases the wind drag of the whole vehicle. Most of the research on the grille only focuses on its impact on the heat dissipation of the engine compartment; there is little research on its influence on the performance of the thermal management system, because it is difficult to solve the real-time data interaction of different dimensional models. So we established the 1D and 3D strong coupling model. The biggest difference from other 1D and 3D coupling models is that we can use the interfaces reserved by the two kinds of software to realize real-time data interaction, and simultaneously analyze the 1D thermal management performance and 3D flow field and temperature field of the engine components. The coupling model is used to study three heat balance conditions. The results show that the heat-sinking capability of the cooling system is the worst under the climbing condition; and the refrigeration capacity of the air-conditioning system is the worst under the idling condition. According to the heat balance results and evaluation index priorities, we determine the simulation process. In this article, first the upper grille is gradually closed; then the flow field, temperature field and evaluation indexes are studied through the strong coupling model to obtain the analysis results of the upper grille; then based on the results, the lower grille is gradually closed, and the analysis results of the lower grille are obtained in the same way. The final simulation results show that on the premise of ensuring the performances of engine cooling system and air conditioning refrigeration system, the air drag coefficient is reduced by 17.5 counts compared with the original vehicle.

Assessment of a 3D ablation material response model for lightweight quartz fiber reinforced phenolic composite

AbstractTo understand the ablation mechanism of materials is crucial for the design of thermal protection system (TPS) for manned reentry vehicles. To investigate the thermal behavior of lightweight quartz fiber reinforced phenolic (LQP) composite subjected to an aerodynamic hyper‐thermal environment, a 3D ablation material response model for the LQP composite is developed with surface and volume ablation in consideration. It is used to predict surface and back temperature, linear ablation velocity, and quality loss rate of the material. The 3D temperature field, pyrolysis degree, gas flow, and pressure field are analyzed as well. To evaluate the accuracy of the model, an ablation test of oxyacetylene flame is adopted on the LQP composite. In the ablation process, the pyrolysis gases propagate primarily through the surface primarily and through the sidewall afterwards. The gas pressure peaks at the early stage rather than increasing constantly. The analysis of thermal insulation mechanism of the LQP composite indicates that the radiation and heat blockage effect are the primary factors to improve the ablation resistance, accounting for 50.0% and 37.3% of the improvement, respectively. The low thermal conductivity determines the admirable thermal insulation performance. The surface temperature of material can be reduced by introducing high emissivity powder into the material, preparing coating on the surface, and adjusting the content of phenolic and silica fiber.

Three-dimensional rapid visualization of flame temperature field via compression and noise reduction of light field imaging

Light field (LF) imaging, as an emerging temperature measurement technique, can simultaneously capture the intensity and direction information of radiation in the combustion flow field and has recently attracted extensive attention. However, the dense sampling of the LF introduces a large amount of redundant information and makes the plenoptic data susceptible to noise pollution, which can significantly affect the performance of 3D temperature field reconstruction. To address this problem, a novel approach, i.e., light field compression and noise reduction (LFCNR), is proposed to extract the main features of the projection matrix and separate the noise-related and signal-related subspaces of the plenoptic data, thus improving the reconstruction accuracy and efficiency. The performance of the proposed LFCNR method and the effect of the hyper-parameters on reconstructed quality are investigated thoroughly. It has been observed that the proposed LFCNR-based method for 3D temperature tomography imaging has higher accuracy, more efficiency, and better anti-noise ability compared to the well-established method. LFCNR can improve the reconstructed temperature accuracy by approximately 20%, and the calculation time is shortened to 10%. Priori smoothing is introduced into the optimization objective to constrain the fluctuation of the retrieval temperature, called LFCNR-PS, which can further improve the reconstructed accuracy of axisymmetric and non-axisymmetric fields about 1.79% and 1.23%. Furthermore, experiments of the LFCNR-based method are carried out to reconstruct the 3D temperature field of ethylene diffusion flames. The reconstructed temperature slices demonstrate that the flame topology can be clearly and rapidly identified at different depths. The efficiency and robustness of the proposed method can be applied to the harsh environment, which will be beneficial to the reliable operation of thermal equipment, the study of turbulent chemical reaction mechanisms, fuel utilization, and the optimization design of the engine combustion chamber.

Application of Tucker Decomposition in Temperature Distribution Reconstruction

Constrained by cost, measuring conditions and excessive calculation, it is difficult to reconstruct a 3D real-time temperature field. For the purpose of solving these problems, a three-dimensional temperature distribution reconstruction algorithm based on Tucker decomposition algorithm is proposed. The Tucker decomposition algorithm is used to reduce the dimension of the measured data, and the processed core tensor is used for the temperature field reconstruction of sparse data. Theoretical analysis and simulations show that the proposed method is feasible; the overall optimization is realized by selecting the appropriate core tensor dimensions; and the reconstruction error is less than 3%. Results indicate that the proposed method can yield a reliable reconstruction solution and can be applied to real-time applications.

3D velocity and temperature distribution measurement and characteristic analysis of swirling combustion

The latest research directions of combustion flow field visualisation and combustion diagnosis have been extended to the development of non-contact, multi-parameter measurement methods for qualitative analysis and multi-dimensional visualisation. Velocity and temperature are important parameters that reflect the characteristics of the combustion flow field and affect the combustion dynamics and combustion mechanism, which have become the keys to characterising and diagnosing the combustion process. Three-dimensional (3D) velocity and temperature fields of combustion were reconstructed in combination with particle image velocimetry (PIV) and deflection tomography temperature measurement methods, and swirl combustion characteristics were studied. A non-premixed burner was designed to generate a swirling flame, and an experimental system was constructed for the simultaneous measurement of velocity and temperature to acquire tracer particles and Moiré fringe images. A 3D particle recognition technology and cross-correlation algorithm were used to reconstruct a 3D combustion velocity field. The fringe displacement analytical technique and deflection angle correction iterative tomography algorithm were used to reconstruct a 3D temperature field. The effects of different swirl numbers and swirl vane positions on the characteristics of the swirl flame shape, velocity distribution, and temperature distribution were investigated. The combustion reaction and field process evolution were explained. Certain characteristics, including heat and mass transfer and flow field transport of swirling combustion, were analysed. The measurement errors were discussed.

Temperature Field of Demagnetization Fault in Permanent Magnet Synchronous Generator

Permanent magnet synchronous generator (PMSG) is widely used in wind power generation systems. However, the temperature of the PMSG may change due to the demagnetization fault of permanent magnets. This paper discusses the loss of heat source distribution for the PMSG, analyzes the thermal conductivity of relevant materials, and determines the boundary conditions for modeling. Then, a three-dimensional (3D) temperature field calculation model was established for the PMSG under demagnetization fault, according to thermal principles and fluid theorems. With the aid of the model, the authors obtained the temperature variation of stator windings, stator cores, and permanent magnets with different demagnetization degrees in different locations. After that, an experimental platform was set up for the PMSG temperature variation under demagnetization fault, and a temperature rise experiment was conducted to verify the effectiveness of our temperature field calculation model and the correctness of the temperature field variation law.

Online reconstruction of 3D temperature field fused with POD-based reduced order approach and sparse sensor data

In power engineering, analysis of the thermal behavior of steam turbine and development of control strategies depend on online evaluations of the temperature fields of in-service components. Due to the complexity of structure and the variability of operating conditions, an online reconstruction technique fused with proper orthogonal decomposition (POD) and sparse sensor data is described herein to monitor the three-dimensional (3D) transient temperature fields of a steam turbine casing. The POD-based reduced order approach was driven by the high-fidelity data of the steam turbine under several start-up conditions, and the POD was used to extract a reduced set of vectors in the orthogonal basis to capture the spatial distribution modes of 3D temperature field. As a result, the temperature fields of steam turbine casing can be reconstructed using the reduced set of vectors in the orthogonal POD basis and the corresponding coefficients, and then it is feasible to online monitor the global temperature distribution by minimizing deviations between the predicted and measured temperatures. The feasibility and accuracy of the reconstruction approach were demonstrated using two numerical examples in comparison with high fidelity data. Finally, real sensor-measured sequential temperatures were used to dynamically determine the real temperature field of the casing. Notably, the reconstructed temperatures were highly consistent with the sensor-measured temperatures, and the time delay of almost every reconstruction process was less than 0.02 s. This proposed reconstruction approach can provide reliable online monitoring for the transient temperature fields of a 3D complex component based on sparse sensors, and it will provide effective support for the design, operation and maintenance.

3D temperature field prediction in direct energy deposition of metals using physics informed neural network

3D temperature field prediction in direct energy deposition of metals using physics informed neural network

Characteristics of the wall temperature field in a mixed convection turbulent boundary layer

The behavior of the heated wall temperature field adjacent to a mixed convection turbulent boundary layer flow was investigated. The wall temperature field was captured using an infrared camera. The Richardson number was varied between experiments to produce a range of mixed convection conditions ranging from buoyancy dominant (RiL = 2.0) to inertia dominant (RiL = 0.01). From the 2D temperature fields recorded, the fluctuating temperature fields and associated low-order statistics were computed. A Fourier-based analysis of the fluctuating temperature field indicated the presence of multiple modes of energy exchange between heated wall and the adjacent turbulent boundary layer flow including energy input, dissipation, and a viscous-convective subrange for RiL ≤ 0.3. The Proper Orthogonal Decomposition (POD) was performed on the fluctuating temperature field. Results show cell-like patterns in low-order POD modes at all tested RiL suggesting a convective cell-like structure in the fluid region adjacent to the interface. The manifestation of these cell-like patterns was found to occur at increasing POD mode number as buoyant contributions decreased relative to inertial contributions.

Flame 3D temperature field reconstruction based on Damped LSQR-LMBC

Light field camera can solve the problems of complex optical path and difficult synchronous trigger of radiation temperature measurement multi camera system, which has some unique advantages in three-dimensional temperature reconstruction of radiation imaging. The LSQR is a classical algorithm for solving the least square problem based on large sparse matrix. When the algorithm is used to reconstruct three-dimensional temperature field, it depends on the initial value of temperature, and the reconstruction accuracy is not ideal when the signal-to-noise ratio is low. In this paper, a damped LSQR-LMBC reconstruction algorithm is proposed. By adding a damped regularization term into the LSQR method, the anti noise performance of flame three-dimensional temperature field reconstruction is improved. By combining the LMBC algorithm, the absorption coefficient and three-dimensional temperature field are solved at the same time. In the numerical simulation part, with the gradual reduction of signal-to-noise ratio, the reconstruction effect of Damped LSQR turns more stable than LSQR. When the signal-to-noise ratio reaches 13.86 dB, the reconstruction accuracy is improved by about 30%. The average reconstruction error of damped LSQR-LMBC is 6.63%. The three-dimensional temperature field distribution of butane flame is consistent with the characteristic of radiation flame combustion. Compared with the temperature measurement data of thermocouple, the relative error is about 6.8%.

Thermal Analysis of Modular Fault‐Tolerant Permanent Magnet Motor Based on Electromagnetic‐Thermal Bi‐Directional Coupling

AbstractCompared with multi‐phase single‐module permanent magnet motors, three‐phase multi‐modularized permanent magnet motors have stronger fault tolerance ability, widely used in aerospace, ship propulsion, and other special fields. Especially in ship direct‐drive propulsion, low speed and high torque modular combined stator fault‐tolerant permanent magnet motor (MCS‐FTPMSM) has high torque density, and fault‐tolerant operation conditions may appear in actual operation, so it is essential to analyze the temperature of the fault‐tolerant motor accurately. This paper analyzes the temperature of MCS‐FTPMSM under different operating conditions and determines the longest operating time of the motor under different fault‐tolerant operating conditions based on the 3D electromagnetic‐temperature bi‐directional coupling method. Among them, the loss of the motor is calculated by the 3D electromagnetic field, which is added to the 3D temperature field as an excitation, and then the material properties in the 3D electromagnetic field are updated according to the calculated temperature distribution. The cyclic iteration method is used to make the calculated temperature deviation less than the given error value. When analyzing the electromagnetic loss of the motor, the field‐circuit coupling method is adopted to consider the influence of the current time‐harmonics of the controller on the loss of the motor during actual operation. Finally, the 12kw100r/min 3 × 3 modular prototype was tested. By comparing the results of experiments, one‐way coupling method (OWCM) and bi‐directional coupling method (BDCM), it is found that the electromagnetic‐thermal bi‐directional coupling can more accurately predict the temperature of the fault‐tolerant motor. © 2021 Institute of Electrical Engineers of Japan. Published by Wiley Periodicals LLC.