High Deposition Rate Research Articles

Preparation of Nano twin copper foil with high elongation and excellent suppression self-annealing via pulse superposition direct current method

Pulse electroplated copper has recently received a great deal of attention from the copper foil and microelectronics industries, as its remarkable microstructure is closely linked to several key properties, including the availability of metallic materials with reduced porosity, fine deposited grains and low electrical resistance. The effects of pulse superimposed direct current (DC) on the microstructure and properties of copper foils were investigated by taking advantage of the high deposition rate of pulse current and the long-term stability and easy control of DC current. Further, tests such as scanning electron microscopy (SEM) and confocal laser microscopy (CLM) were used to characterize the surface micromorphology of the copper foils, and the influence of the self-annealing effect at ambient temperature was explored using electron backscattering diffraction (EBSD). The results show that pulsed superimposed DC can obtain copper foils with a small profile and high tensile strength with a Sz of only 0.670 μm, σust 538.67 MPa and an elongation of 4.90%. Further, the specific additive MESS effectively suppresses the mechanical property degradation caused by self-annealing of copper foils, with a tensile strength reduction of only 0.39%.

Impact of process parameter on the behavior of pyrocarbon deposition in chemical vapour infiltration (CVI) process

Carbon-carbon composite manufactured by deposition of pyrocarbon (PyC) through chemical vapor infiltration (CVI) has the key issue of being process parametric sensitive which necessitates the detailed study of the effect of process parameters on the rate of PyC deposition. Conventional method of studying the parametric effect by changing one variable at a time keeping the other variables constant has a limitation of more number of experiments and missing the interaction effect among the variables. Here, the effect of process parameters including temperature, pressure, methane gas flow rate, and nitrogen gas flow rate on the mass gain and PyC deposition was studied by Taguchi method, a statistical optimization method, which has the advantage of very few experiments performed at specific pairs of process parameters only. The experiments were performed at three levels of the process parameters. Carbon-Carbon composite material is processed through the CVI process where PyC was deposited on porous carbon fiber preforms at various process conditions as per the Taguchi method. The impact of gas residence time, Reynolds number, Prandtl number, and Peclet number were also investigated. It was observed that the CVI process parameters significantly affect the rate of PyC deposition. Optimized CVI process parameters are essential for achieving a high rate of PyC deposition to reduce the processing time. The findings have revealed that a higher PyC deposition rate arises under high temperatures, pressure, methane gas flow rate, and optimal nitrogen gas flow rate. The effect of the critical interaction of the CVI process parameters on the rate of PyC deposition was also obtained. Based on the experimental studies, process guidelines are proposed for the densification of carbon fibers preform to realize C/C composite products.

Physics of microscale freeform 3D printing of ice

Ice is emerging as a promising sacrificial material in the rapidly expanding area of advanced manufacturing for creating precise 3D internal geometries. Freeform 3D printing of ice (3D-ICE) can produce microscale ice structures with smooth walls, hierarchical transitions, and curved and overhang features. However, controlling 3D-ICE is challenging due to an incomplete understanding of its complex physics involving heat transfer, fluid dynamics, and phase changes. This work aims to advance our understanding of 3D-ICE physics by combining numerical modeling and experimentation. We developed a 2D thermo-fluidic model to analyze the transition from layered to continuous printing and a 3D thermo-fluidic model for the oblique deposition, which enables curved and overhang geometries. Experiments are conducted and compared with model simulations. We found that high droplet deposition rates enable the continuous deposition mode with a sustained liquid cap on top of the ice, facilitating smooth geometries. The diameter of ice structures is controlled by the droplet deposition frequency. Oblique deposition causes unidirectional spillover of the liquid cap and asymmetric heat transfer at the freeze front, rotating the freeze front. These results provide valuable insights for reproducible 3D-ICE printing that could be applied across various fields, including tissue engineering, microfluidics, and soft robotics.

Evolution of Material Properties and Residual Stress with Increasing Number of Passes in Aluminium Structure Printed via Additive Friction Stir Deposition.

Additive friction stir deposition (AFSD) is an emerging solid-state additive manufacturing process with a high deposition rate. Being a non-fusion additive manufacturing (AM) process, it significantly eliminates problems related to melting such as cracking or high residual stresses. Therefore, it is possible to process reactive materials or high-strength alloys with high susceptibility to cracking. Although the residual stresses are lower in this process than with the other AM processes, depending on the deposition path, geometry, and boundary conditions, residual stresses may lead to undesired deformations and deteriorate the dimensional accuracy. Thermal cycling during layer deposition, which also depends on the geometry of the manufactured component, is expected to affect mechanical properties. To this day, the influence of the deposit geometry on the residual stresses and mechanical properties is not well understood, which presents a barrier for industry uptake of this process for large-scale part manufacturing. In this study, a stepped structure with 4, 7, and 10 passes manufactured via AFSD is used to investigate changes in microstructure, residual stress, and mechanical property as a function of the number of passes. The microstructure and defects are assessed using scanning electron microscopy and electron backscatter diffraction. Hardness maps for each step are created. The residual stress distributions at the centreline of each step are acquired via non-destructive neutron diffraction. The valuable insights presented here are essential for the successful utilisation of AFSD in industrial applications.

Acoustic Signal-Based Defect Identification for Directed Energy Deposition-Arc Using Wavelet Time-Frequency Diagrams.

Several advantages of directed energy deposition-arc (DED-arc) have garnered considerable research attention including high deposition rates and low costs. However, defects such as discontinuity and pores may occur during the manufacturing process. Defect identification is the key to monitoring and quality assessments of the additive manufacturing process. This study proposes a novel acoustic signal-based defect identification method for DED-arc via wavelet time-frequency diagrams. With the continuous wavelet transform, one-dimensional (1D) acoustic signals acquired in situ during manufacturing are converted into two-dimensional (2D) time-frequency diagrams to train, validate, and test the convolutional neural network (CNN) models. In this study, several CNN models were examined and compared, including AlexNet, ResNet-18, VGG-16, and MobileNetV3. The accuracy of the models was 96.35%, 97.92%, 97.01%, and 98.31%, respectively. The findings demonstrate that the energy distribution of normal and abnormal acoustic signals has significant differences in both the time and frequency domains. The proposed method is verified to identify defects effectively in the manufacturing process and advance the identification time.

Design of laser-powder coupling for high-speed laser direct energy deposition

High-speed laser direct energy deposition (DED-LB) is developed to enhance deposition efficiency while maintaining build quality, compared to conventional DED-LB. The core of designing high-speed DED-LB involves formulating the laser-powder coupling, through optimizing nozzle structural and deposition process parameters. This study developed an analytical model to delineate the coupling mechanisms between laser beam and discontinuous coaxial powder stream (DCPS) comprised of individual single powder streams (SPSs). A data pretreatment method, involving gray processing, normalization, and renormalization of the thermal images successively, was applied to validate the model. Simulation results indicate that the DCPS spot size and SPS particle temperature distribution are predominantly influenced, respectively, by the nozzle structural and deposition process parameters. Through jointly designing the nozzle structural and deposition process parameters, a high deposition rate of high-speed DED-LB, which is 1.7 times that of conventional DED-LB, was achieved. This paper pioneers a new design methodology for high-speed DED-LB.

The Effect of Interlayer Delay on the Heat Accumulation, Microstructures, and Properties in Laser Hot Wire Directed Energy Deposition of Ti-6Al-4V Single-Wall.

Laser hot wire directed energy deposition (LHW-DED) is a layer-by-layer additive manufacturing technique that permits the fabrication of large-scale Ti-6Al-4V (Ti64) components with a high deposition rate and has gained traction in the aerospace sector in recent years. However, one of the major challenges in LHW-DED Ti64 is heat accumulation, which affects the part quality, microstructure, and properties of as-built specimens. These issues require a comprehensive understanding of the layerwise heat-accumulation-driven process-structure-property relationship in as-deposited samples. In this study, a systematic investigation was performed by fabricating three Ti-6Al-4V single-wall specimens with distinct interlayer delays, i.e., 0, 120, and 300 s. The real-time acquisition of high-fidelity thermal data and high-resolution melt pool images were utilized to demonstrate a direct correlation between layerwise heat accumulation and melt pool dimensions. The results revealed that the maximum heat buildup temperature of the topmost layer decreased from 660 °C to 263 °C with an increase to a 300 s interlayer delay, allowing for better control of the melt pool dimensions, which then resulted in improved part accuracy. Furthermore, the investigation of the location-specific composition, microstructure, and mechanical properties demonstrated that heat buildup resulted in the coarsening of microstructures and, consequently, the reduction of micro-hardness with increasing height. Extending the delay by 120 s resulted in a 5% improvement in the mechanical properties, including an increase in the yield strength from 817 MPa to 859 MPa and the ultimate tensile strength from 914 MPa to 959 MPa. Cooling rates estimated at 900 °C using a one-dimensional thermal model based on a numerical method allowed us to establish the process-structure-property relationship for the wall specimens. The study provides deeper insight into the effect of heat buildup in LHW-DED and serves as a guide for tailoring the properties of as-deposited specimens by regulating interlayer delay.

Oriented growth of 5-inch optical polycrystalline diamond films by suppressing dark features

Optical diamond materials are essential for infrared optical windows, microwave windows, and laser windows due to their exceptional properties. However, dark features inside the diamond are significant factors limiting optical properties, particularly at high deposition rates. This work focuses on adjusting crystallographic parameters to prepare (110) oriented optical-grade polycrystalline diamond films, aiming to mitigate dark features. Diamond films deposited via microwave plasma chemical vapor deposition (MPCVD) exhibit discernible quality stratification. Characterization analysis of diamond film samples with varying levels of black defects reveals a correlation: films with higher dark feature content tend to exhibit a preference for the (111) orientation, accompanied by a significant presence of penetration twins and interstitial voids. Conversely, transparent diamond films demonstrate a prominent (110) orientation, featuring numerous contact twins that alleviate competition from penetration twins and original grains during growth. Electron backscatter diffraction (EBSD) and scanning electron microscope (SEM) results reveal that transparent diamond films cultivated with a pronounced preference for the (110) orientation manifest consistent and seamless contact twins, leading to fewer dark features and improved optical transmittance. In contrast, (111) oriented diamond film exhibits numerous penetration twins, and holes form between them. Based on the analysis, 5-inch optical polycrystalline diamond films with (110) orientation were achieved successfully by suppressing dark features.

A Study of Directionality Effects in Three-Beam Coaxial Titanium Wire-Based Laser Metal Deposition.

Coaxial wire-based laser metal deposition is a versatile and efficient additive process that can achieve a high deposition rate in the manufacturing of complex structures. In this paper, a three-beam coaxial wire system is studied, with particular attention given to the effects of the deposition direction and laser beam orientation on the resulting bead geometry symmetry. With the three-beam laser delivery, the laser spot pattern is not always symmetric with respect to the deposition direction. Single titanium beads are deposited in different directions and at varying deposition rates, and the bead profile is quantitatively scored for multiple symmetry measures. Through an analysis of variance, the deposition direction and deposition rate were found to be insignificant with respect to the resulting bead symmetry for the developed measures. The bead symmetry and geometry are important factors in determining if a build is free of critical defects, and in this study, it is shown that the three-beam coaxial wire deposition setup is a directionally independent process.

Experimental Studies on the Anisotropic Fatigue Behaviour of IN718 Fabricated via Wire Arc Additive Manufacturing

Wire and arc additive manufacturing (WAAM) offers promise in creating large complex structures due to its flexibility and high material deposition rates. The nickel-based alloy IN718 is favoured for WAAM due to its weldability and compatibility. However, WAAM can introduce issues like anisotropic grain structure, porosity, and residual stresses which can lead to directional variations in tensile, fatigue, and fracture behaviour. This paper studied the WAAM process of IN718, utilising cold metal transfer (CMT). The optimised CMT-WAAM parameters for IN718 were identified to as a wire feed speed of 8–10 m/min and a torch travel speed of 0.5–0.7 m/min, resulting in stable deposition and minimal defects. Nevertheless, columnar grain structures were observed in the build direction (BD), with coarse grains in the wall-length direction (WD). This anisotropic microstructure coupled with stress concentrators, contributes to the directional dependence observed in tensile properties, fatigue endurance, and crack growth. The investigation revealed superior ductility in the BD compared to the WD. Interestingly, the fatigue endurance testing showed a longer life in the WD compared with the BD, attributed to stronger stress concentrators in the BD specimens. However, when examining a cracked specimen, the fatigue crack propagated faster in the WD rather than the BD.

Research on the Welding Process and Weld Formation in Multiple Solid-Flux Cored Wires Arc Hybrid Welding Process for Q960E Ultrahigh-Strength Steel.

This paper proposes a novel welding process for ultrahigh-strength steel. The effects of welding parameters on the welding process and weld formation were studied to obtain the optimal parameter window. It was found that the metal transfer modes of solid wires were primarily determined by electrical parameters, while flux-cored wires consistently exhibited multiple droplets per pulse. The one droplet per pulse possessed better welding stability and weld formation, whereas the short-circuiting transfer or one droplet multiple pulses easily caused abnormal arc ignition that decreased welding stability, which could easily lead to a "sawtooth-shaped" weld formation or weld offset towards one side with more spatters. Thus, the electrical parameters corresponding to one droplet per pulse were identified as the optimal parameter window. Furthermore, the weld zone (WZ) was predominantly composed of AF, and the heat-affected zone (HAZ) primarily consisted of TM and LM. Consequently, the welded joint still exhibited excellent mechanical properties, particularly toughness, despite higher welding heat input. The average tensile strength reached 928 MPa, and the impact absorbed energy at -40 °C for the WZ and HAZ were 54 J and 126 J, respectively. In addition, the application of triple-wire welding for ultrahigh-strength steel (UHSS) demonstrated a significant enhancement in post-weld deposition rate, with increases of 106% and 38% compared to single-wire and twin-wire welding techniques, respectively. This process not only utilized flux-cored wire to enhance the mechanical properties of joints but also achieved high deposition rate welding.

Optimized electrophoretic zinc oxide coating on SS316L with enhanced hardness and scratch resistance

The major issues in electrophoretic deposition of ZnO coating on SS316L are lack of adhesive strength, control of electrophoretic mobility, and the presence of cracks in the coating. The novelty of the present study is mainly focused on optimizing the electrophoretic deposition parameters by varying the concentration of the ZnO NPs (1.0 g/L and 1.5 g/L) and the applied voltages (30 V and 40 V) to minimize these coating defects. The impact of nanoparticle concentrations and applied voltages on the morphology, roughness, phase composition, functional groups, hardness, surface energy, and scratch resistance of ZnO coatings was analyzed. Various deposition conditions produced different crystal sizes ranging from 16 to 24 nm. Among the deposition conditions, the ZnO-3 coating demonstrated an increased crystal size with decreased microstrain. However, a higher applied voltage of 40 V in the ZnO-3 coating significantly increased the electrophoretic mobility of the NPs, leading to the agglomeration of the NPs and the formation of larger crystals. Furthermore, morphological analysis confirmed uniform distribution and higher deposition rates in the ZnO-2 coating. The ZnO-2 coating deposited at a concentration of ZnO NPs (1.5 g/L) and a lower applied voltage (30 V), exhibited higher coating hardness (216 HV), lower surface roughness (0.207 µm), low surface energy, and better adhesive strength than the other three ZnO coatings. Thus, the optimized electrophoretic coating of ZnO-2 on SS316L emerged as a solution to reduce the cracks, improve the adhesion with better control over electrophoretic mobility.

The effects of electrolyte composition and deposition voltage on the copper-nickel alloy micropillars fabricated by Jet ECD

With the rapid development of micro electronic component technology, higher requirements are put forward for high performance and high precision manufacturing process. In this paper, copper-nickel alloy micropillars were manufactured by jet electrochemical deposition (Jet ECD) technology with high deposition rate, aiming to provide an effective material and process solution for the manufacture of micro-thermocouples and other components. By optimizing the process parameters such as electrolyte composition, pH value and deposition voltage, the homogeneous deposition of copper-nickel alloy micropillar was realized. The cross-section morphology and elementary composition of the deposition micropillars were characterized in detail by using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results show that the adjusted formula and process parameters can stably manufacture copper-nickel alloy micropillars with a nickel-copper ratio (close to 0.8), and compact, void free microstructure.

Tailoring the morphology of vertically aligned carbon nanorod arrays grown on Co catalyst nanoparticles and using MW-PECVD

This study reports a direct approach to synthesizing vertically aligned carbon nanorod arrays (VA-CNRA) using microwave plasma-enhanced chemical vapor deposition (MW-PECVD) at 300 °C, on cobalt (Co) catalyst nanoparticles grown by thermal annealing (750 °C) of 10 nm thick Co layer deposited by radio frequency (RF) magnetron sputtering. To grow the VA-CNRA, the gas ratio in the plasma was optimized, focusing on the kinetics of the source gas dissociation and recombination. The reduced concentrations of acetylene (C2H2) impede the optimal alignment of CNRA in the absence of the steric hindrance, resulting in their horizontal growth along the direction of gas flow via the “kite-mechanism”. However, at a higher gas flow ratio, the attractive van der Waals potential among the CNRs was anticipated to induce aggregation when they arrive in proximity and vertical growth alignment of the nanorods via the higher deposition rates. Carbon nanorod films were analyzed using various spectroscopic techniques to understand the growth orientations, which suggests that the carbon nanorods were formed via the base-growth mechanism. Nano flower-like VA-CNRA were formed at higher C2H2/H2 ratios. Notably, a distinct flower-like structure with whisker-like nanostructure petals was formed at a C2H2/H2 flow ratio of ∼0.57. Compared to other nanorod structures, VA-CNRA, grown at optimal gas ratio, exhibited superior crystalline graphite, with 76 % sp2 CC bonding along with a maximum of I2D/IG, and a minimum of ID/IG intensity ratio in the Raman data. High-resolution TEM confirmed robust growth of CNRs, with an average diameter of ∼370 ± 3 nm. This innovative method enables large-scale production of VA-CNRA with high surface areas for energy applications.

The development of B/Cr co-doped DLC coating by FCVA deposition system and its tribological properties at 300 °C

The diamond-like carbon (DLC) coating prepared using filtered cathodic arc deposition (FCVA) lost its promising wear resistance under high temperatures. Element-doped DLC coatings have been investigated to suppress carbon oxidation reaction and subsequently enhance the wear resistance in high-temperature environments. Previous research clarified the excellent tribological properties of boron-doped DLC (B-DLC) but identified challenge such as arc discharge extinguishment and coating declamation (under high-temperature friction test). In this study, the introduction of Argon gas (10 sccm) during the deposition process stabilized stable arc discharge, resulting in high hardness and deposition rate. Moreover, a chromium interlayer and varying concentration of Cr dopant (0.5 %, 1.0 %, 3.0 % at.) were added to B-DLC to develop a stable, co-doped DLC with low friction and high wear resistance. Raman spectroscopy and nano-indentation revealed an increase in the disordered carbon structure and reduction in hardness and Young's Modulus with Cr doping. Macroscopic ball-on-disk friction test, showed 1 % Cr-doped B-DLC (a-C:B:Cr1) coating exhibited super low friction (avg. coefficient 0.02) and a low specific wear rate (<5.0 × 10−6 mm3/Nm). Raman spectroscopy indicated that the transferred graphite-like tribo-film onto the surface of Si3N4 counterparts contributed to stable low friction. Additionally, XPS analysis on the DLC coatings' wear track suggested the rich BB bond might contribute to its high wear resistance. This successful improvement on element-doped DLC prepared by FCVA provided valuable insights for further exploration of DLC coating applied to various working situations.

Full-field validation of finite cell method computations on wire arc additive manufactured components

Wire arc additive manufacturing enables the production of components with high deposition rates and the incorporation of multiple materials. However, the manufactured components possess a wavy surface, which is a major difficulty when it comes to simulating the mechanical behavior of wire arc additively manufactured components and evaluation of experimental full-field measurements. In this work, the wavy surface of a thick-walled tube is measured with a portable 3D scanning technique first. Then, the surface contour is considered numerically using the finite cell method. There, hierarchic shape functions based on integrated Legendre polynomials are combined with a fictitious domain approach to simplify the discretization process. This enables a hierarchic p-refinement process to study the convergence of the reaction quantities and the surface strains under tension–torsion load. Throughout all considerations, uncertainties arising from multiple sources are assessed. This includes the material parameter identification, the geometry measurement, and the experimental analysis. When comparing experiment and numerical simulation, the in-plane surface strains are computed based on displacement data using radial basis functions as ansatz for global surface interpolation. It turns out that the finite cell method is a suitable numerical technique to consider the wavy surface encountered for additively manufactured components. The numerical results of the mechanical response of thick-walled tubes subjected to tension–torsion load demonstrate good agreement with real experimental data, particularly when employing higher-order polynomials. This agreement persists even under the consideration of the inherent uncertainties stemming from multiple sources, which are determined by Gaussian error propagation.

Jet Electroforming of High-Aspect-Ratio Microcomponents by Periodically Lifting a Necked-Entrance Through-Mask.

High-aspect-ratio micro- and mesoscale metallic components (HAR-MMMCs) can play some unique roles in quite a few application fields, but their cost-efficient fabrication is significantly difficult to accomplish. To address this issue, this study proposes a necked-entrance through-mask (NTM) periodically lifting electroforming technology with an impinging jet electrolyte supply. The effects of the size of the necked entrance of the through-mask and the jet speed of the electrolyte on electrodeposition behaviors, including the thickness distribution of the growing top surface, deposition defect formation, geometrical accuracy, and electrodeposition rate, are investigated numerically and experimentally. Ensuring an appropriate size of the necked entrance can effectively improve the uniformity of deposition thickness, while higher electrolyte flow velocities help enhance the density of the components under higher current densities, reducing the formation of deposition defects. It was shown that several precision HAR-MMMCs with an AR of 3.65 and a surface roughness (Ra) of down to 36 nm can be achieved simultaneously with a relatively high deposition rate of 3.6 μm/min and thickness variation as low as 1.4%. Due to the high current density and excellent mass transfer effects in the electroforming conditions, the successful electroforming of components with a Vickers microhardness of up to 520.5 HV was achieved. Mesoscale precision columns with circular and Y-shaped cross-sections were fabricated by using this modified through-mask movable electroforming process. The proposed NTM periodic lifting electroforming method is promisingly advantageous in fabricating precision HAR-MMMCs cost-efficiently.

Characterization of polycrystalline BiFeO3 films prepared by magnetic-field-assisted 90° off-axis pulsed laser deposition

Polycrystalline BiFeO3 (BFO) films were prepared on a Pt/TiO2/SiO2/Si substate using magnetic field-assisted 90° off-axis pulsed laser deposition (PLD). We have successfully obtained polycrystalline BFO films owing to a high deposition rate derived by the confinement of the plume under a magnetic field. The obtained polycrystalline BFO films have a droplet-free surface morphology and a columnar-like microstructure. A RT ferroelectric hysteresis loop is obtained, and at the same time, the remanent polarization of 90 μC cm−2 and the reduced coercive field of 178 kV cm−1 are confirmed. Also, an evolution of the polarization switching is observed by the piezoresponse force microscopy. In this study, we provide a possible route to realize the polycrystalline film growth which has a good quality in a 90° off-axis deposition system using magnetic field-assisted PLD.

New chronology of K-feldspar isochron optical dating (iIRSL) in the late Pleistocene coastal aeolian deposits of Southeast China

Old red sand (ORS), which developed during the late Pleistocene, is widely distributed along the coasts of the western Pacific and Indian Ocean.The Optically Stimulated Luminescence (OSL) dating technology have primarily determined its sedimentary age. However, in tropical and subtropical regions, chemical weathering can impact the calculation of environmental dose rates, potentially leading to age biases whose magnitude remains uncertain.Recently, advance in the OSL dating technique, the new K-feldspar isochron dating method (iIRSL), have determined its depositional age. This approach effectively enhances the accuracy of age data by accounting for variations in past dose rates caused by chemical weathering and changes in water content during sample burial. This study used the iIRSL method to conduct infrared stimulated luminescence signal tests on ORS samples from the Haitan Island, south China. Five grain sizes of K-feldspar grains were extracted from each sample during experimentation. The single aliquot regenerative dose method (SAR) was utilized to determine the equivalent dose for each grain size and calculate age using the isochron method (iIRSL). Furthermore, it compared the iIRSL ages with quartz age (SAR). The results indicate that: (1) This study obtained four iIRSL ages, which are consistent with the ages obtained from quartz (SAR) within a reasonable range, ranging from 62.13 ± 4.85 to 39.44 ± 4.85 ka BP. (2) Comparison of the simulation results of different weathering degrees using the iIRSL method and K-feldspar two-step IRIR methods indicates that the iIRSL method can effectively mitigate the impact of chemical weathering on age determination, giving more reliable iIRSL ages. (3) The ORS along the southern coast of China mainly deposited during Marine Isotope Stages 5, 4, and 3, exhibiting relatively higher deposition rates during MIS 5 and MIS 3 at approximately 30 cm/ka and 15 cm/ka respectively. This suggests that the ORS was predominantly deposited during periods of elevated sea levels. However, it is important to note that the data from MIS 5 may have been influenced by the absence of samples from this particular stage and limitations in dating methods, resulting in a lower frequency-density of deposition ages during MIS 5 and creating an “illusion” of sediment interruption.

Numerical investigation on ash accumulation characteristics of serrated spiral finned tube heat exchanger in waste heat utilization

In this study, a comprehensive loose fouling model is established to investigate the fouling characteristics of fly ash on serrated spiral finned tube heat exchangers. This model considers the energy change during particle collision, the velocity change after particle rebound and slip, and the amplification of fouling time under mixed particle sizes. The results show that the fouling position, morphology, and height obtained by the theoretical model agree well with the experiments. Besides, the serrated spiral fin is the main fouling position due to its high fin ratio and the strong disturbance effect. The 5 μm particles have the highest deposition rate, and fine particles tend to adhere to the second row of finned tubes due to the consumption of initial kinetic energy by the first row. With an increase in fin height by 6 mm, the deposition rate only increases by 1.2 %, while an increase in sawtooth height by 5 mm results in a deposition rate increase of 14.3 %. When the flue gas velocity is less than 7 m/s, finned tubes arranged in a staggered configuration provide the best combination of heat transfer, flow resistance, and anti-ash accumulation performance.