Melting Process Research Articles

The key to high-quality metallic glass casting: Interfacial reaction associated with vacuum induction melting process procedures

Even though vacuum induction melting (VIM) is widely employed in the industrial production of bulk metallic glasses (BMGs), the effect and mechanism of the interfacial reaction between the melt and the oxide ceramic crucible on BMG formations are not yet fully understood. Here, the influences and mechanisms of the interfacial reaction on a Zr-based BMG (Vit 105) subjected to various melting temperatures and holding times are revealed by employing experiments and theoretical calculations. We find that the degree of interfacial reaction is intriguingly correlated with the process parameters during VIM processing, leading to an increase in the oxygen content of the alloy and the reaction layer thickness. Besides, the increase of oxygen content also induces variations in the ordering and shear transformation zone (STZ) size of the BMGs, thus resulting in the precipitation of a nanoscale fcc phase and affecting the mechanical properties and reliability under deformation of the alloy. Furthermore, thermodynamic and kinetic parameters involved in the interfacial reaction, such as the molar Gibbs free energy of each element, the apparent activation energy, etc., are obtained, providing a comprehensive understanding of the transport processes at play. Our findings provide new insights into the preparation of BMGs by VIM and may be expanded to other melting techniques to accelerate the commercial application of metallic glasses.

Effect of blade geometry on the powder spreading process in additive manufacturing

In powder-bed-based additive manufacturing, the quality of the powder bed is closely related to the geometry of the blade used during the powder spreading process. In this study, the spreading process with the vertical blade, inclined blade, and round blade with different radii was performed by discrete element method to investigate the effects of blade geometry on powder spreading. The results show that at the same spreading parameters, the round blade caused the highest density than inclined blade and vertical blade. Increasing the round blade radius can improve the packing density of the powder bed, but it has little effect on the uniformity. The increase in packing density is related to the transitional smoothness of the blade surface at the entrance of the powder bed. The smoother the shape transition of the blade surface at the powder bed entrance, the powders enter the powder bed more gently, so more powders enter the powder bed, resulting in higher packing density. The results may provide suggestions for improving the laser melting process.

Application of bionic topology to latent heat storage devices

Latent heat storage is employed to address the intermittent supply of renewable energy, and enhancing heat transfer in phase change materials (PCMs) is pivotal for achieving effective heat storage. Currently, the predominant method for improving heat transfer is through the integration of high thermal conductivity fins into heat storage devices. This study introduces an innovative design of a three-tube phase change heat storage device created through bionic topology optimization. The impact of parameters such as penalty factors and filtering radius on the topology structure is analyzed, and the optimal range of fin volume fraction is determined based on energy storage density and energy storage time. Considering the influence of natural convection on heat transfer properties, four distinct heat storage models, including topology-optimized fins, are compared. The heat transfer and flow properties during the processes of melting and solidification, as well as their field synergy, are investigated. The study reveals that the optimized fins exhibit more bionic fractal structures and a larger, more uniform heat transfer contact area. Compared to traditionally optimized fin structures, this research reduces the heat storage time of the three-tube heat storage device by 21.96 % and the heat release time by 38.13 % without compromising the maximum heat storage capacity. The topology-optimized fins demonstrate a fractal dimension similar to natural fractal structures such as branches, leaf veins, antlers, and snowflakes. This study presents a novel bionic structural design approach for high-performance latent heat storage systems.

Selective Laser Melting Process Optimization and Mechanical Properties Evolution of AlSi10Mg by Determining Temperature of the Build Chamber using Arduino IDE and Coding Algorithm

Selective Laser Melting Process Optimization and Mechanical Properties Evolution of AlSi10Mg by Determining Temperature of the Build Chamber using Arduino IDE and Coding Algorithm

A good balance between the efficiency of ionizing radiation shielding and mechanical performance of various tin-based alloys: Comparative analysis

The Sn-Bix (x = 30, 40, 50, 60 and 70%) radiation shielding alloys were prepared using a melting process of the alloying material in a ceramic crucible at 200 °C for 120 min. The structural characterization for synthesized samples was carried out using X-ray Diffraction technique (XRD). The hardness and elastic properties of the prepared alloys was measured using micro-indentation creep technology and tensile test machine respectively. XRD pattern indicated that that the crystal size of Sn phase is lowered by increasing Bi concentration in the Sn matrix. The hardness decreases as the dwell time increases. The hardness values and elastic properties (in terms of young modulus) were significantly improved due to the decrease in the crystallite size by increasing Bi content. The stress exponent (n) value increase by increasing Bi content which mean that the mechanical properties improved due to increment of resistance. Furthermore, the produced alloys' nuclear shielding ability was investigated. The μm values were calculated using MCNP simulation code and XCOM software over a broad energy range of 0.015 MeV–15 MeV with good agreement between them. Several characteristics are estimated in order to properly understand the researched alloy's radiation and properties of neutron shielding. The findings showed that a higher Bi concentration causes the crystal size to decrease, improving the radiation shielding and mechanical qualities. The alloy Sn-70% Bi has a maximum increase of vicker hardness, tensile strength, and young's modulus. The findings of the shielding parameters indicate that the alloys under study are efficient gamma shielding materials in contrast to other typical shielding materials and materials that have been examined recently. The highest mechanical efficiency and rather strong gamma-ray shielding capabilities are found in the Sn–70Bi alloy. Owing to its ability to effectively balance mechanical performance and shielding, the Sn–70Bi are approved for use in radiation protection. In addition, when compared to all other manufactured alloys, typical neutron shielding materials, and recently investigated materials, the results further demonstrate that the Sn–70Bi alloy has the best neutron attenuation capability. Furthermore, in terms of mass stopping power (MSP) and projected range (PR), the Sn–70Bi alloy demonstrates the most effective attenuation for alpha particles (He+2) and protons (H+1). These results imply that the Sn–70Bi alloy provide superior mechanical performance and nuclear shielding for a range of applications including industrial, medicinal, and nuclear waste storage in the future.

A Comparative Study on the Melt Crystallization of Biodegradable Poly(butylene succinate-co-terephthalate) and Poly(butylene adipate-co-terephthalate) Copolyesters.

As an important biodegradable and partially biobased copolyester, poly(butylene succinate-co-terephthalate) (PBST) possesses comparable thermal and mechanical properties and superior gas barrier performance when compared with poly(butylene adipate-co-terephthalate) (PBAT), but it was found to display poorer melt processability during pelletizing and injection molding. To make clear its melt crystallization behavior under rapid cooling, PBST48 and PBST44 were synthesized, and their melt crystallization was investigated comparatively with PBAT48. PBST48 showed a PBAT48-comparable melt crystallization performance at a cooling rate of 10 °C/min or at isothermal conditions, but it showed a melt crystallization ability at a cooling rate of 40 °C/min which was clearly poorer. PBST44, which has the same mass composition as PBAT48, completely lost its melt crystallization ability under the rapid cooling. The weaker chain mobility of PBST, resulting from its shorter succinate moiety, is responsible for its inferior melt crystallization ability and processability. In comparison with PBAT48, PBST48 displayed higher tensile modulus, and both PBST48 and PBST44 showed higher light transmittance. The findings in this study deepen the understanding of PBST's properties and will be of guiding significance for improving PBST's processability and application development.

A computational analysis of the impact of nanofluids (Al2O3)on the PCM melting process in a rectangular container

The effect of nanofluids on the melting process of PCMs (RT58 paraffin wax) in a rectangle container is a topic of interest for many researchers. The use of nanofluids in PCMs can lead to faster and more efficient melting, resulting in improved energy storage and cooling performance. This paper has studied four cases with varying percentages of nanofluids. The percentage of nanofluid in PCM can affect the material's thermal conductivity and heat transfer performance. By varying the percentage of nanofluids, researchers aim to optimize the use of these in PCMs to achieve the best melting performance. Findings have shown that increasing the percentage of nanofluids in PCM can lead to improved thermal conductivity and heat transfer performance. However, at high concentrations (30% percent), the viscosity of the nanofluid can increase, leading to a decrease in heat transfer performance. Results show that at 30 min, PCM with 30% nanofluid melts 13.79% more than PCM without. Using 20% nanofluid in the PCM results in a melting percentage of 7.41%, decreasing to 3.85% at 10%.The specific application and the type of nanofluid used determine the optimal concentration of nanofluid in PCMs. This study is important for the use of phase-change materials in the cooling of large electronic devices.

Controllable fabrication of shape memory epoxy resin filament by polymerization-melting-mixing-drawing process and performance regulation

ABSTRACT This work controlled the polymerization reaction, melting, and mixing processing of a mixture including epoxy resin and polyethylene glycol (PEG) by a pulverizer, to effectively develop high-performance shape memory epoxy/PEG (EPP) filaments. The process parameters of polymerization-melting-mixing-drawing were determined through the extrusion force investigation. The results showed that EPP mixtures could be developed into filaments through polymerization-melting-mixing-drawing process, reducing the spinning temperature and filament diameter from 300°C and 31 mm to 235°C and 13 mm, respectively. The Fourier transform infrared spectra confirmed the complete polymerization of epoxy resin and the stable existence of PEG. EPP filaments developed through the polymerization-melting-mixing-drawing process have exhibited controllable dynamic thermal mechanical properties and Tg, excellent shape recovery effects, and adjustable stimulus temperature. This work developed shape memory EPP filaments through a polymerization-melting-mixing-drawing process, with controllable spinnability and adjustable stimulus temperature, providing a reference for high-performance filament fabrication and process optimization.

Microstructural characterization of Stellite 6 alloy processed by electron beam melting

Stellite 6 alloy was subjected to electron beam melting (EBM) processing in this study. The main phases in the alloy are α-Co, ε-Co, M23C6 (M = Cr, Co, W, etc.), and M7C3 (M = Cr, Co, W, etc.) carbides. The microstructure of the EBM-processed Stellite 6 alloy comprises grains of relatively uniform sizes, with an average grain size of 11.1 μm. There is a relatively minor internal strain within the alloy. The majority of grains exhibit low intragranular misorientations, approximately around 0.5°, while a minority of grains display relatively larger intragranular misorientations, around 2.8°. The dominant {100} texture was developed in the build direction because of the fast growth of the <100> direction for a cubic crystal structure during solidification. The vertically aligned columnar grains contribute to the development of the <100> texture along the build direction. The elongated direction of columnar grains was parallel to the temperature gradient direction. This competitive growth direction at the solid-liquid interface results in slight tilts in the pole figures. The eutectic carbide phases are uniformly distributed along the grain boundaries. The cube–cube orientation relationships between the matrix and M23C6 carbide phase were identified as [001]α//[111]M23C6. The low stacking fault energy of the Stellite 6 alloy resulted in the formation of a high density of stacking faults within the grains. The interactions between stacking faults of different orientations were observed. Primary M7C3 carbides were found to transform into secondary M23C6 carbides, with a phase transition process observed where secondary carbides M23C6 surrounded primary carbides M7C3.

Numerical Investigation of Melting in Pressurized Water Reactor Fuel Rod Considering Operational Parameters of the Core

The meltdown of a fuel rod is a severe accident resulting from the overheating of the reactor core. In the present study, a numerical investigation of this process, focusing on the loss of coolant has been conducted. The objective of this study is to conduct a numerical simulation of transient heat conduction and melting at various points within a typical pressurized water reactor fuel rod. In this analysis, heat conduction in the radial direction of a fuel rod, including the UO2 fuel pellet, the gap, and the zircaloy cladding, is investigated. The FRAPCON steady-state code is employed to calculate the operational parameters of the fuel rod. The calculated parameters, such as coolant and fuel temperatures, fission gas fraction, gap heat transfer coefficient, and burnup, are utilized to evaluate and compare the melting phenomena at different time intervals. In the investigation of the phase change in various parts of the pellet and fuel rod, the explicit finite difference (FD) method is utilized with enthalpy instead of temperature-dependent equations. Finally, the temperature history, phase change, and melting map at different points along the radial and axial directions of the fuel rod during coolant loss and heat transfer coefficient reduction are evaluated based on various operating parameters of the core. To enhance the quality of the results, an uncertainty analysis of effective parameters is conducted. According to this analysis, the heat transfer coefficient of the coolant under accident conditions (0.2 ± 5% kWm−2K−1) and the thermal conductivity of the fuel have the most significant impact on the temperature history and melting process. Highlights include the following: 1. The meltdown of a nuclear fuel rod is analyzed under a loss-of-coolant accident. 2. The enthalpy formula is discretized by the explicit FD numerical method. 3. Effective parameters in melting, such as coolant temperature, burnup, and gap heat transfer coefficient, are obtained by FRAPCON. 4. The temperature history, phase changes, and melting map of various radial points within the fuel pellet and cladding along the axial direction of the fuel rod are determined.

Synthesis of Polycyclic Olefinic Monomers from Norbornadiene for Inverse Vulcanization: Structural and Mechanistic Consequences.

The preparation of high-sulfur content organosulfur polymers has generated considerable interest as an emerging area in polymer science that has been driven by advances in the inverse vulcanization polymerization of elemental sulfur with organic comonomers. While numerous new inverse vulcanized polysulfides have been made over the past decade, insights into the mechanism of inverse vulcanization and structural characterization of the high-sulfur-content copolymers remain limited in scope. Furthermore, the exploration of new molecular architectures for organic comonomer synthesis remains an important frontier to enhance the properties of these new polymeric materials. In the current report, the first detailed study on the synthesis and inverse vulcanization of polycyclic rigid comonomers derived from norbornadiene was conducted, affording a quantitative assessment of polymer microstructure for these organopolysulfides and insights into the inverse vulcanization polymerization mechanism for this class of monomers. In particular, a stereoselective synthesis of the endo-exo norbornadiene cyclopentadiene adduct (Stillene) was achieved, which enabled direct comparison with the known exo-exo norbornadiene dimer (NBD2) previously used for inverse vulcanization. Reductive degradation of these sulfur copolymers and detailed structural analysis of the recovered sulfurated organic fragments revealed that remarkable exo-stereospecificity was achieved in the inverse vulcanization of elemental sulfur with both these polycyclic dienyl comonomers, which correlated to the robust thermomechanical properties associated with organopolysulfides made from NBD2 previously. Melt processing and molding of these sulfur copolymers were conducted to fabricate free-standing plastic lenses for long-wave infrared thermal imaging.

Optimizing Selective Laser Melting of Inconel 625 Superalloy Through Statistical Analysis of Surface and Volumetric Defects

This article delves into optimizing and modeling the input parameters for the selective laser melting (SLM) process on Inconel 625. The primary aim is to investigate the microstructure within the interlayer regions post-process optimization. For this study, 100 layers with a thickness of 40 µm each were produced. Utilizing the design of experiments (DOE) methodology and employing the Response Surface Method (RSM), the SLM process was optimized. Input parameters such as laser power (LP) and hatch distance (HD) were considered, while changes in microhardness and roughness, Ra, were taken as the responses. Sample microstructure and surface alterations were assessed via scanning electron microscopy (SEM) analysis to ascertain how many defects and properties of Inconel 625 can be controlled using DOE. Porosity and lack of fusion, which were due to rapid post-powder melting solidification, prompted detailed analysis of the flaws both on the surfaces of and in terms of the internal aspects of the samples. An understanding of the formation of these imperfections can help refine the process for enhanced integrity and performance of Inconel 625 printed material. Even slight directional changes in the columnar dendrite structures are discernible within the layers. The microstructural characteristics observed in these samples are directly related to the parameters of the SLM process. In this study, the bulk samples achieved a microhardness of 452 HV, with the minimum surface roughness recorded at 9.9 µm. The objective of this research was to use the Response Surface Method (RSM) to optimize the parameters to result in the minimum surface roughness and maximum microhardness of the samples.

Exploring optimal Li composite electrode anodes for lithium metal batteries through in situ X-ray computed tomography

The uncontrolled Li dissolution/deposition dynamics and rapid Li pulverizations hinder the widespread deployment of Li metal batteries (LMB). Designing a Li composite electrode possessing a mechanically robust and lithiophilic three-dimensional (3D) framework represents a promising strategy to address these challenges. This study involves the preparation of three uniquely tailored Li-B-Mg composites using a combined metallurgical process of melting, casting, and rolling, along with the synergistic application of in situ X-ray computed tomography (CT) and post-mortem failure analysis to explore the most promising composite electrode candidate for LMBs. During the in-depth investigation, the optimal 70Li-B-Mg composite electrode stands out due to its robust skeleton fiber structure, uniform Li dissolution/deposition characteristics and high capacity of free-Li. Its promising prospects for enabling high-performance LMBs are showcased by the superior performance of the built Li||O2, Li||LiFePO4, Li||NCM622 and Li||NCM811 battery systems. This work offers a novel approach for exploring universally applicable and robust Li composite electrodes to realize high-performance LMBs using in situ CT analysis.

Thermal energy storage, heat transfer, and thermodynamic behaviors of nano phase change material in a concentric double tube unit with triple tree fins

The contribution of this study is the proposal of a synergistic composite enhancement strategy involving tree fins and nanomaterials to improve the low thermal performance of phase change material (lauric acid) in a typical double tube latent heat thermal energy storage unit. The effects of nanoparticle concentrations and tree fin branching angles on the fluid dynamics, melting time, heat transfer, energy storage, and entropy generation characteristics were investigated. By employing tree fins, the melting time was respectively reduced by up to 60.20% and 36.05% compared to the finless case and the rectangular fins, while the energy storage power was respectively boosted by up to 143.36% and 37.45%. The increase of nanoparticle concentration was beneficial for melting heat transfer, and the dendritic fins with a bottom angle of 90° and a top angle of 30° yielded the highest energy storage performance. The total entropy generation of the melting process was mainly governed by the thermal entropy generation, and it showed a decreasing trend with the increase of time. In contrast to the finless configuration, the incorporation of fins diminished the integrated entropy generation value. Similarly, an elevation in nanoparticle concentration also led to a reduction of the integrated entropy generation value.

Synthesis and Characterization of Metallic (Fe‐Ni, Fe‐Ni‐Si) Reference Materials for SIMS 34S/32S Measurements

Secondary ion mass spectrometry (SIMS) is often used to determine the sulfur contents and isotope ratios of metallic alloys in meteorites or high‐pressure experimental samples. However, SIMS analyses involve calibration and the determination of instrumental mass fractionation in reference materials with a matrix composition similar to that of the unknown samples. To provide metallic reference materials adapted to S measurements via SIMS, we synthesised a series of twenty‐eight alloys comprising four FeNi(±Si) compositions (Fe95Ni5, Fe90Ni10, Fe80Ni20, and Fe80Ni15Si5) with S contents varying from 100 μg g−1 to 4 g/100g using the “melt spinning” method, which guarantees that the metal alloys are rapidly quenched at ~ 106 K s−1. Sulfur contents were determined at the Service d'Analyse des Roches et Minéraux at the CRPG and absolute δ34S values were determined by multi‐collector ICP‐MS (MC‐ICP‐MS, ThermoScientific Neptune) and isotope ratio mass spectrometry (Thermoscientific Delta V). A δ34S value of 16.01 ± 0.31‰ was consistently obtained using the MC‐ICP‐MS, which was indistinguishable of the δ34S value of the FeS starting material (15.95 ± 0.08‰). It suggests that S did not undergo isotopic fractionation during the melting process. Of fifteen samples containing ≤ 5000 μg g−1 S, SIMS measurements with 15‐μm‐diameter spots were repeatable to within 10% relative (1 standard deviation, 1s) for S contents and 2‰ for δ34S values. However, samples containing &gt; 5000 μg g−1 S showed FeNi–FeS immiscibility, leading to minor dispersion of the S mass fractions and δ34S values. No matrix effect was observed for Fe‐Ni, Si, or S contents in terms of the calibration curves and instrumental mass fractionation. We ultimately recommend eight samples as reliable reference materials for S isotopic measurements by SIMS, which we can share worldwide with other laboratories.

Molecular dynamics study on phase change properties and their nano-mechanism of sugar alcohols: Melting and latent heat

Sugar alcohol phase change materials have gained considerable attention for heat storage in recent years owing to their higher thermal conductivity and larger latent heat compared to traditional paraffin materials. However, knowledge about the reason of large latent heat and latent heat difference among diverse sugar alcohols as well as the mechanism of melting process remains elusive. In this study, molecular dynamics simulation was employed to investigate the melting process and latent heat of four sugar alcohols (glycerol, erythritol, arabinitol, and mannitol). Melting points and latent heat of fusion were determined first, different melting temperatures were observed under different one-dimensional heat conduction directions in several sugar alcohols. It was found that the strength of intermolecular interactions within molecular crystal layers has a positive correlation with the anisotropic melting tendencies, which can be more intuitively reflected by the difference in the number of hydrogen bonds within the molecular layers. In addition, the decomposition of the latent heat of fusion revealed that the latent heat is mainly composed of van der Waals and Coulombic contributions, where the interaction between hydroxyl groups accounts for a major part. Hydrogen bond analysis demonstrated that the latent heat of fusion is partly due to the breakage of hydrogen bonds during the phase transition of melting. It was also noted that the differences in the hydrogen bonding lifetimes between different sugar alcohols may be related to the magnitude of latent heat of fusion. Erythritol and mannitol which coincidentally happened to have an even number of carbon atoms can fulfill the properties of better PCMs compared to glycerol and arabinitol, which have an odd number of carbons. Those results will pave the way for better design optimization and performance evaluation of sugar alcohols as phase change materials.

Entropy optimization in multigrade motor oil based nanofluid: a spectral and sensitivity analysis with particle shape and dispersion effects

PurposeThis study aims to enhance heat transfer efficiency while minimizing friction factor and entropy generation in the flow of Nickel zinc ferrite (NiZnFe2O4) nanoparticles suspended in multigrade 20W-40 motor oil (as specified by the Society of Automotive Engineers). The investigation focuses on the effects of the melting process, nonspherical particle shapes, thermal dispersion and viscous dissipation on the nanofluid flow.Design/methodology/approachThe fundamental governing equations are transformed into a set of similarity equations using Lie group transformations. The resulting set of equations is numerically solved using the spectral local linearization method. Additionally, sensitivity analysis using response surface methodology (RSM) is conducted to evaluate the influence of key parameters on response function.FindingsHigher dispersion reduces entropy production. Needle-shaped particles significantly enhance heat transfer by 27.65% with melting and reduce entropy generation by 45.32%. Increasing the Darcy number results in a reduction of friction by 16.06%, lower entropy by 31.72% and an increase in heat transfer by 17.26%. The Nusselt number is highly sensitive to thermal dispersion across melting and varying volume fraction parameters.Originality/valueThis study addresses a significant research gap by exploring the combined effects of melting, particle shapes and thermal dispersion on nanofluid flow, which has not been thoroughly investigated before. The focus on practical applications such as fuel cells, material processing, biomedicine and various cooling systems underscores its relevance to sectors such as nuclear reactors, tumor treatments and manufacturing. The incorporation of RSM for friction factor analysis introduces a unique dimension to the research, offering novel insights into optimizing nanofluid performance under diverse conditions.

Investigating swastika fins to enhance heat transfer and melting process of nano-enhanced phase change materials units

The ability of nano-enhanced phase change materials (NePCM) to store thermal energy has garnered the interest of scientists. An approach to enhancing thermal conductivity involves the implementation of novel fins that facilitate a more rapid PCM melting process. The present investigation assessed the efficacy of eight distinct fin configurations in augmenting the thermal properties of NePCM. Four occurrences featured swastika fins, whereas the remaining instances exhibited a 45-degree tilt angle. The enthalpy-porosity method was implemented to simulate heat transfer and melting process. The present research investigates the effects of fin tilt angles and swastika fins on the NePCM-thermal energy storage (TES) unit's mean temperature, liquid percentage, and thermal energy storage. Compared to the straight fins (Case 1), the long-arm swastika fins (Case 4) decreased the melting time by a factor of 2.3. In addition, Case 4 demonstrated exceptional thermal energy storage capabilities. Case 7 demonstrated that the tilting angle significantly affected the melting time, with a reduction of 34.9 %, compared to the non-tilted swastika fins utilized in Case 2. However, the increase in the fins' length was more substantial. According to the findings of this study, Case 4 is the optimal fin configuration for NePCM-TES.

Additive manufacturing of quartz glass using coaxial wire feeding technology

This study explores the process of coaxial wire feeding and melting for quartz additive manufacturing using Direct Energy Deposition (DED). Quartz glass, valued for its excellent mechanical, optical, and thermal properties, is widely used in semiconductor, aerospace, and optical communication industries. Additive manufacturing offers advantages such as cost-effective materials, rapid formation, and customization of structures. However, current methods for additive manufacturing of quartz glass often result in low quality or require complex post-processing, particularly for optical components. In optics, there is a demand for high-quality, straightforward processes, and custom-shaped quartz glass. This article presents a coaxial wire feeding mechanism wherein quartz wire is fed vertically downward along the optical axis into the melting zone created by a CO2 laser, facilitating smooth material deposition onto the molten zone’s surface. Laser power, wire feeding speed, substrate movement speed, and defocusing distance are key factors influencing the quality of single-layer quartz glass formation. Positive defocusing was found to have a beneficial impact on single-layer quartz glass additive manufacturing. Subsequently, optimized process parameters enabled the production of uniformly cross-sectional single-layer quartz glass. Microscopic morphology analysis and temperature field simulation were conducted on the experimental results before and after optimization. Finally, complex quartz glass structures were additively manufactured using the optimized experimental parameters. Results demonstrate that coaxial wire feeding technology has significant potential for achieving uniform dimensions and complex structures in quartz glass additive manufacturing.

The role of atmospheric conditions in the Antarctic sea ice extent summer minima

Abstract. Understanding the variability of Antarctic sea ice is still a challenge. After decades of modest growth, an unprecedented minimum in the sea ice extent (SIE) was registered in summer 2017, and, following years of anomalously low SIE, a new record was established in early 2022. These two memorable minima have received great attention as single cases, but a comprehensive analysis of summer SIE minima is currently lacking. Indeed, other similar events are present in the observational record, although they are minor compared to the most recent ones, and a full analysis of all summer SIE minima is essential to separate potential common drivers from event-specific dynamics in order to ultimately improve our understanding of the Antarctic sea ice and climate variability. In this work, we examine sea ice and atmospheric conditions during and before all summer SIE minima over the satellite period up to 2022. We use observations and reanalysis data and compare our main findings with results from an ocean–sea ice model (NEMO–LIM) driven by prescribed atmospheric fields from ERA5. Examining SIE and sea ice concentration (SIC) anomalies, we find that the main contributors to the summer minima are the Ross and Weddell sectors. However, the two regions play different roles, and the variability of the Ross Sea explains most of the minima, with typical negative SIE anomalies about twice as large as the ones in the Weddell Sea. Furthermore, the distribution of SIC anomalies is also different: in the Weddell Sea, they exhibit a dipolar structure, with increased SIC next to the continent and decreased SIC at the sea ice margin, while the Ross Sea displays a more homogenous decrease. We also examine the role of wintertime sea ice conditions before the summer SIE minima and find mixed results depending on the period: the winter conditions are relevant in the most recent events, after 2017, but they are marginal for previous years. Next, we consider the influence of the atmosphere on the SIE minima, which is shown to play a major role: after analyzing the anomalous atmospheric circulation during the preceding spring, we find that different large-scale anomalies can lead to similar regional prevailing winds that drive the summer minima. Specifically, the SIE minima are generally associated with dominant northwesterly anomalous winds in the Weddell Sea, while a southwesterly anomalous flow prevails in the Ross Sea. Finally, we investigate the relative contribution of dynamic (e.g., ice transport) and thermodynamic (e.g., local melting) processes to the summer minima. Our results indicate that the exceptional sea ice loss in both the Ross and Weddell sectors is dominated at the large scale by thermodynamic processes, while dynamics are also present but with a minor role.