Melting Process Research Articles

Experimental assessment of the heat shielding performance by the integration of phase change material and liquid cooling plate

This research focuses on innovative stealth equipment by integrating a liquid cooling plate and phase change material (PCM), and the temperature rise on the cold surface and PCM melting rate is reported to illustrate the PCM thermal behavior in lifting the heat shielding performance. Results show that the integrated PCM system is effective in delaying the temperature rise within a certain time. A slower temperature rise on the cold surface is found at the first 1200 s, and a significant acceleration in the temperature rise is given within 1200 s ∼ 2000 s as the heat flood breaks through the PCM layer. The PCM melting rate increases rapidly and then rises slowly, and the complete melting time is shortened as increasing heat power. The heat shielding performance is significantly reduced with increasing the liquid flow rate, and the influence of the coolant temperature on the temperature rise becomes more and more prominent as the completion of the PCM melting process. A slower temperature rise is observed at the lower PCM phase transition temperature, and a further increase in the PCM covering layer has little influence on the temperature rise at the initial stage.

Instabilities in the formation of single tracks during selective laser melting process

Instabilities in the formation of single tracks during selective laser melting process

A combined uncertainty and sensitivity analysis of melting in a cubical cavity, Part A: Model validation

Latent heat thermal energy storage systems exploit the solid–liquid phase transition of a material to store thermal energy almost isothermally with high energy density. Numerical methods are increasingly being used for the targeted design of these storage systems. The problem, however, is that the results obtained with these methods – despite a frequently shown near-perfect agreement between validation experiments and simulation results – are subject to large uncertainty. To illustrate the extent of this problem and to show approaches to solving it, a combined uncertainty and sensitivity analysis of the melting process of a paraffin (octadecane) in a cuboid heated from one side is carried out in this two-paper series. In part A, we present the model and validate it; in part B we use it to carry out the combined uncertainty and sensitivity analysis. The validation of the model is performed with the help of experimental results. For this purpose, we measure the liquid phase fraction, the position of the phase boundary, the velocity field in the liquid and the temperature inside the test capsule. We make sure that the experimental results are reproducible. Systematic deviations are discussed and, if possible, the results are corrected for their value. When measuring the velocity field using particle image velocimetry (PIV), the greatest systematic deviation is due to the inhomogeneous refractive index field in the liquid phase. Finally, it is shown that, in the present case, the influence is very low if constant material properties evaluated at the mean temperature are taken for each phase compared to a temperature-dependent implementation. An exception is the density. If the density change during melting is not taken into account the deviation of the melt fraction lies between 6 and 8%. In summary, the validation of the numerical model is very satisfactory and demonstrates the suitability of the model for performing the investigations of the part B paper.

Numerical simulation of physical field during different ultrasonic power assisted casting of 7085 aluminum alloy

High‐energy ultrasound has the effect of purifying the aluminum (Al) melt and improving the uniformity of temperature and flow field distribution. In this paper, a finite element numerical model of ultrasonic‐assisted casting of 7085 Al alloy melt was established, and the changes of acoustic pressure field, temperature field and flow field in the solidification process of alloy melt with different ultrasonic power were investigated. The numerical simulation results show that the thickness of the 7085 Al melt mushy zone decreases by 89 mm, 97 mm, 108 mm, 114 mm and 99 mm, respectively, compared without ultrasonic (WNU) when the ultrasonic power was 150 W, 350 W, 550 W, 750 W and 950 W. The area of the alloy mushy zone increases by 38.1%, 43.5%, 61.0%, 206.5% and 45.6%, respectively. According to numerical simulation results, when the ultrasonic power was 750W, it had the best effect on improving the macroscopic physical field, increasing the mass and heat transfer rate in the center of the Al melt. Meanwhile, the experimental results of industrial melting and casting of 7085 large‐scale Al alloy ingots were basically consistent with the numerical simulation, which provided technical support for ultrasonic‐assisted fabrication of large‐scale 7085 Al alloy ingots.This article is protected by copyright. All rights reserved.

Analysis of the melting process of carbon-bearing pellets in iron bath, slag bath and graphite crucible

Background With the increase in the amount of scrap steel in society, the proportion of electric furnace steelmaking is increasing year by year, especially in China. Due to the high Zn content, the electric furnace arc dust (EAFD) needs to be recovered by non-blast furnace process. Due to EAFD containing a large amount of zinc ferrite, it needs to be recovered by fire process. It is a promising process to melt the EAFD pellets to get the discount and zinc-rich secondary ash. Methods To clarify the melting behavior of pellets in the metallurgical process, the slag phase diagram and the effect of temperature and FeO on slag viscosity were calculated using FactSage, and the melting process of electric furnace arc dust (EAFD) pellets in a graphite crucible, iron bath, and slag bath were experimentally investigated. Results The experimental results show that the viscosity of the slag system decreases with increasing temperature and FeO content, and the effect of FeO on viscosity is greater. The viscosity decreased from 0.305 to 0.276 Pa·s when the FeO content in the slag was increased from 0 wt. % to 2 wt.% at 1773 K. The melting process of the EAFD pellets in an iron bath and graphite crucible was consistent, and after the formation of liquid-phase slag in the pellets, the liquid-phase slag was diffused to melt the pellets. Conclusions The iron bath improved the heat transfer conditions of the pellets, reducing the smelting time from 600 to 360 s. The slag bath promoted the slagging reaction of the contact part to change the pellet melting process and increase the pellet melting speed, and the EAFD pellets melted within 240 s in a slag bath.

Effect of Oligoricinoleic Acid on Degradation of Polylactic Acid

ABSTRACT The objective of this research is to explore the impact of oligoricinoleic acid (ORA) on the degradation of polylactic acid (PLA). ORA was synthesized from ricinoleic acid using tin (II) 2-ethylhexanoate as a catalyst. The chemical structures of the obtained ORA were confirmed by Fourier-transform infrared spectrometer (FT-IR) and proton nuclear magnetic resonance spectroscopy (1H-NMR). PLA/ORA films were prepared through the casting method by varying ORA concentrations as 0.1%wt, 0.3%wt, 0.5%wt, 1.0 wt%, and 3.0%wt. Degradation of the films via hydrolysis was studied by soaking the films in deionized water and stirring at 120 rpm in an incubator at 37°C. Alterations in the structure and properties of the films were investigated after soaking for 7, 14, 21, and 28 days using ultraviolet-visible spectroscopy (UV-Vis), Fourier-transform infrared spectrometer (FTIR), scanning electron microscope (SEM), X-ray diffraction (XRD), differential scanning calorimeter (DSC), thermogravimetric analysis (TGA), and universal testing machine (UTM). Gel permeation chromatography (GPC) was performed to confirm the decrease in molecular weight (MW). The presence of 3%wt ORA could promote both ductility and degradation of PLA films. ORA further enhances thermal stability, indicating potential for prevention of thermal degradation during melt processing.

The effect of isocyanate on the properties of poly(butylene adipate‐co‐terephthalate)/Kenaf fiber composites

AbstractPoly(butylene‐adipate‐co‐terephthalate) (PBAT)/Kenaf fiber composites was prepared by the melt processing technique with various compositions to investigate the general properties. While the Young's modulus of the composite was profoundly improved, the tensile strength and elongation at break exhibited a significant diminished with the incorporation of kenaf fibers due to the poor interfacial adhesion between PBAT and Kenaf fibers. The Halpin‐Tsai model was applied, and the similar behavior of Young's modulus for the composite as compared to experimental results was calculated. The micro‐voids and cavitation were clearly confirmed by morphological observation. Reactive compatibilization with HDI improved the compatibility between PBAT and Kenaf fibers, and the mechanical performance was significantly enhanced due to improved interfacial adhesion. The PBAT/Kenaf composites with a reactive compatibilization showed considerable improvement of storage modulus, G′ in terminal region as well. The stable thermal stability could be also beneficial for thermal processing technique. The addition of Kenaf fiber resulted in a liquid‐like behavior decreasing elasticity of the PBAT/Kenaf composites. The HDI had a profound effect on increasing elasticity with solid‐like behavior resulting in enhancing the G′ and η* of the PBAT/Kenaf fiber composites due to the improved interfacial adhesion as confirmed from the morphological observation.Highlights Kenaf fiber has a great effect on improvement of the modulus for PBAT/Kenaf composites The optimized PBAT/Kenaf composite composition is 96/4 wt% ratio for the composite HDI is found to be a good compatibilizer for PBAT and Kenaf fiber Reactive compatibilization enhances the interfacial adhesion between PBAT and Kenaf fiber The compatibilized PBAT/Kenaf composites have the better mechanical performance

Chemical-free Reactive Melt Processing of Biosourced Poly(butylene-succinate-adipate) for Improved Mechanical Properties and Recyclability

Chemical-free Reactive Melt Processing of Biosourced Poly(butylene-succinate-adipate) for Improved Mechanical Properties and Recyclability

Absorbing capabilities of additively manufactured lattice structure specimens for crash applications: Damage tolerant design and simulations

AbstractIn the present work, the influence of defects on the compressive response of octet‐truss AlSi10Mg lattice structure specimens produced with a selective laser melting process is investigated. The defect population in one cell, in two cells, and cubic specimens composed of 27 cells has been assessed with micro‐computed tomography (micro‐CT) analyses. The statistical distributions of the characteristic defect sizes, i.e., the equivalent diameter, the volume, and the surface, assessed in the lattice structure specimens and in volumes randomly extracted from a rectangular bar have been compared. Finally, the compressive behavior of lattice structure specimens has been simulated with a simplified damage‐tolerant finite element model accounting for the influence of defects and compared with experimental results. The analyses have proven that the defect population in volumes extracted from a rectangular bar can provide reliable simulated results, even if micro‐CT inspections of a unit cell or specimens made of several cells are suggested.

Influence of particle parameters on the melting/migration of silicon particles and turbulent heat transfer during CCZ monocrystalline silicon growth

The Continuous Czochralski (CCZ) is a promising approach for preparing low-cost high-quality monocrystalline silicon in the photovoltaic field. To investigate the coupled mechanism of silicon particles melting/migration and melt turbulent heat transfer during the CCZ monocrystalline silicon growth, based on the Euler–Lagrange framework, a three-dimensional transient heat-mass transfer model is developed using the LES method considering the heat exchange between the silicon particles and the silicon melt as well as the particles size change. In addition, we investigated the effects of key silicon particle parameters such as feeding temperature, particle size and feeding speed, on the silicon particles melting/migration and melt turbulent heat transfer. The results show that appropriately increasing the feeding temperature and speed contributes to achieve more concentrated particles distribution and weaken the movement of silicon particles towards the crystalline interface simultaneously, which conduce to eliminate the adverse impact of continuous feeding on monocrystalline silicon growth. And the feeding temperature has a great effect on the temperature fluctuation near the crystalline interface. In addition, when the feeding speed exceeds 1.5m/s, increasing feeding speed has no significant effect on the particles distribution and melting process. Besides, the feeding particle size has a significant effect on the maximum penetration depth of particles. The small silicon particles prefer moving to the crystalline interface driven by thermophoretic force, which is detrimental to the high-quality CCZ monocrystalline silicon growth.

Improving phase change heat transfer in an enclosure partially filled by uniform and anisotropic metal foam layers

Anisotropic metal foams exhibit exceptional potential for improving the efficiency of latent heat thermal energy storage (LHTES) units by enhancing heat transfer and thermal energy storage rates. This study explores the largely uncharted area of thermal behavior of anisotropic metal foams in varied configurations and enclosure designs. The research focuses on an LHTES unit with a specific channel configuration, constructed using copper and containing three layers of copper metal foam, one of which is anisotropic and infused with paraffin wax. The finite element method was utilized to manage the complexities emerging from phase change, and the anisotropic angle varied from 0 to 90° in three different placements of the AMFL: top, middle, or bottom of the enclosure. The ideal design was achieved with an AMFL in the middle with a 0°angle, resulting in a 3.7 % reduction in melting time and approximately a 2.3 % reduction in solidification time. However, AMFL designs at the middle placement with a 75° anisotropic angle were less effective, hampering the melting and solidification processes, thus potentially extending charging and discharging times. The study concludes that the placement and angle of the AMFL layer are vital for the heat transfer capabilities of phase change materials. AMFL at the middle with a 0° angle optimally leverages temperature gradients, enhancing heat transfer compared to other investigated cases. An AMFL in the middle with a 0° angle exhibits approximately 7.1 % and 6.3 % improvements for melting fractions of 0.9 and 0.95, respectively, underscoring its potential for efficient thermal energy storage.

Dramatically Accelerating II-I Crystal Phase Transition of Polybutene‑1 by In Situ Incorporation of H-Shape Long-Chain-Branching Structures.

This communication reports an effective strategy helping address the long-troubling melt processing issue of isotactic polybutene-1 (i-PB) caused by its extremely slow II-I crystal phase transition. The solution lies in a facile synthesis of i-PB containing H-shape long-chain-branching structures (LCB-i-PB) by applying a so-called ω-alkenylmethyldichlorosilane copolymerization-hydrolysis (ACH) chemistry to butene-1 polymerization with Ziegler-Natta or metallocene catalysts. It is evident that the H-shape LCB structures effectively enhance chain entanglements of i-PB and induce an over-the-board acceleration of the overall melt crystallization process including nucleation, form II crystallization, and form II-form I phase transition. As i-PB usually requires up to a week to reach equilibrium of the II-I phase transition, it is found that with LCB-i-PB such a transition is almost finished within as short as 24 h to even higher degrees.

Flash melting amorphous ice.

Water can be vitrified if it is cooled at high rates, which makes it possible to outrun crystallization in so-called no man's land, a range of deeply supercooled temperatures where water crystallizes rapidly. Here, we study the reverse process in pure water samples by flash melting amorphous ice with microsecond laser pulses. Time-resolved electron diffraction reveals that the sample transiently crystallizes despite a heating rate of more than 5 × 106 K/s, even though under the same conditions, vitrification can be achieved with a similar cooling rate of 107 K/s. Moreover, we observe different crystallization kinetics for amorphous solid water and hyperquenched glassy water. These experiments open up new avenues for elucidating the crystallization mechanism of water and studying its dynamics in no man's land. They also add important insights into the laser melting and revitrification processes that are integral to the emerging field of microsecond time-resolved cryo-electron microscopy.

The Nucleated Poly(L-lactic acid): The Role of a Phenylacetic Hydrazide Derivative

The melt-crystallization, cold-crystallization, melting behaviors, thermal stability, and optical properties of poly(L-lactic acid) (PLLA) nucleated by a phenylacetic hydrazide derivative (DAPH) were investigated. The melt-crystallization confirmed DAPH’s heterogeneous nucleation role in improving PLLA’s poor crystallization capability, concurrently DAPH loading, cooling rate and final melting temperature were three key factors affecting PLLA’s melt-crystallization behaviors. The results from cold-crystallization indicated that the addition of DAPH could accelerate PLLA’s cold-crystallization via cold-crystallization peak’s shift toward the lower temperature side as DAPH loading increased. Through analysis of PLLA/DAPH’s multiple melting behaviors after melt-crystallization, it was found that DAPH loading, the previous melt-crystallization and heating rate determined PLLA/DAPH’s melting processes after melt-crystallization; and PLLA/DAPH’s melting processes after isothermal crystallization depended on the previous crystallization temperature. A drop in thermal decomposition temperature for 5 wt.% mass loss suggested that pure PLLA has better thermal stability compared with PLLA/DAPH. Additionally, the introduction of DAPH could not improve PLLA’s transparency, in contrast, the haze of PLLA was increased greatly owing to the existence of DAPH.

Selection of phase change material for latent heat thermal energy storage using a hair-pin heat exchanger: Numerical Study

Abstract Phase change materials (PCMs) are promising for storing thermal energy as latent heat, addressing power shortages. Growing demand for concentrated solar power systems has spurred the development of latent thermal energy storage, offering steady temperature release and compact heat exchanger designs. This study explores melting and solidification in a hairpin-type heat exchanger (HEX) using three PCMs (RT 50, RT 27, and RT 35). A 3D model of the hairpin type heat exchanger (HEX) is drawn using Ansys-workbench. High-temperature fluid/Low-temperature fluid (HTF/LTF) with Stefan numbers (0.44, 0.35, and 0.23) flows through the inner pipe to charge the outer pipe's PCM. The Enthalpy-porosity model is used to study the melting and solidification of various PCMs, and the results were compared. Also, individual thermophysical properties that affect the heat transfer during the melting and solidification process have been discussed. It is observed that low thermal conductivity material with high latent heat is preferred for cold climates. In this study, RT 27 excels in cold climates due to extended solidification time, while RT 50 is effective in tropical regions due to its high melting points and lower latent heat.

High barrier polyesters based on 2,5-furandicarboxylic acid and disulfide bond: Smart degradation induced by low concentrations of redox reagent

Bio-based and biodegradable polymers opens up opportunities to overcome resource depletion and plastic pollution. However, the degradation mechanism based on ester bond breakage makes it difficult to achieve controllable degradation induced by external stimuli. In this work, we present a new 2,5-furandicarboxylic acid-based copolyesters (PBFDi) by partially replacing carbon–carbon backbones with disulfide bonds and discuss the influence of disulfide bonds on thermal stability, crystallization behavior, mechanical and barrier properties of polyesters. They could maintain stable for 1 h at processing temperatures of 220 °C, meeting the needs of long-term melt processing. The asymmetric structure of the furan ring and the slower free rotation of disulfide bonds help restrict the mobility of chains and obstruct gas permeation, resulting in 9.3–126.7 times increase in O2 barrier than commercial PBAT. With the introduction of small amount (≤40 %) of disulfide bond units, the hydrolysis rate is relatively slow and can maintain stable during storage and use. As expected, the copolyesters show redox dual-responsive degradation. Even at low concentrations (0.01 M and 0.1 M) of H2O2, the transition from hydrophobicity to hydrophilicity can be achieved, expected to accelerate the hydrolysis of PBFDi. The fast cleavage of disulfide bonds induced by DTT could be influenced by the copolymerized FDCA units. Lastly, the redox dual-responsive mechanism is elucidated, and how the rigid FDCA co-monomers affect the redox dual responsiveness is also clarified.

Estimating Stage-Frequency Curves for Engineering Design in Small Ungauged Arctic Watersheds

The design of hydraulic structures in the Arctic is complicated by shallow relief, which cause unique runoff processes that promote snow-damming and refreeze of runoff. We discuss the challenges encountered in modeling snowmelt runoff into two coastal freshwater lagoons in Utqiaġvik, Alaska. Stage-frequency curves with quantified uncertainty were required to design two new discharge gates that would allow snowmelt runoff flows through a proposed coastal revetment. To estimate runoff hydrographs arriving at the lagoons, we modeled snowpack accumulation and ablation using SnowModel which in turn was used to force a physically-based hydraulic runoff model (HEC-RAS). Our results demonstrate the successful development of stage-frequency curves by incorporating a Monte Carlo simulation approach that quantifies the variability in runoff timing and volume. Our process highlights the complexities of Arctic hydrology by incorporating significant delays in runoff onset due to localized snow accumulation and melting processes. This methodology not only addresses the uncertainty in snow-damming and refreeze processes which affect the arrival time of snowmelt inflow peaks, but is also adaptable for application in other challenging environments where secondary runoff processes are predominant.

FORMULATION AND EVALUATION OF MEDICATED CHEWING GUM OF TERBUTALINE SULFATE FOR THE ASTHAMATIC MANAGEMENT

Objective: This experiment aimed to improve the bioavailability of terbutaline sulfate by formulating it as medicated chewing gum. Methods: By employing zein as the gum foundation and the melting process, chewing gum was created with the desired outcome. Results: All formulations had thicknesses ranging from 3.61 to 3.68 mm in the lateral direction and from 5.22 to 5.41 mm in the longitudinal direction. All formulations had hardness values between 3.1 and 3.4 kg/cm2. All formulations had weight variations between 1.6% and 2.1%. All of the formulations had the same quantity of medication, which varied between 95.2 and 96.9%. Drug release from terbutaline sulfate chewing gum (TCGs) in simulated saliva (pH 6.8 buffer solution) was investigated by examining the samples up to a half-hour later. It was discovered that the drug release from the formulations ranged from 64.28 to 89.56% in 30 min. Conclusion: The release of the medication was reduced when the gum basis (zein) content in the formulations was increased. It was discovered that, after 30 min, TCG1 emitted the most proportion of terbutaline sulfate. As a result, it may be regarded as the finest formulation available.

Investigating combined effects of varying gravity and heat flux direction on the melting dynamics of phase change material in space

The present work investigates the combined effect of varying gravity and heat flux direction with respect to gravity on the melting dynamics of Phase Change Material. Similar conditions are relevant to applications in space, at different space infrastructures, such as orbiting satellites, as well as various extraterrestrial surface assets, landers, and rovers. The numerical simulations are performed to study the melting dynamics of a paraffin-based phase change material with Prandtl number Pr ≈ 71 and Stefan number Ste ≈ 0.33 inside a differentially heated square enclosure. The mathematical model employs a control volume-based enthalpy porosity approach to simulate the melting process inside enclosure. The direction of the incoming heat flux relative to the gravity vector is defined in terms of an orientation angle, which is varying circularly with a step of 45°, whereas the gravity level is ranging from the terrestrial surface value g to 0.2g to analyze the melting process over a wide range of Rayleigh number 100 ≤ Ra ≤ 107. The study provides a detailed insight into the attributes of heat transfer, flow dynamics, and energy storage, along with a quantitative analysis of the transition between various melting regimes and temporal fluctuations in the performance parameters. The findings demonstrate that the mutual orientation between the directions of incoming heat flux and gravity, as well as the value of the latter, significantly affect features of the convective motion in the liquid phase, as well as the entire thermally driven heat transfer within the domain. In particular, for the oppositely directed gravity and heat flux, the melted fluid closely resembles Rayleigh-Bénard convection with the presence of multicellular flow structures, while at other orientation angles, except for a co-directed gravity and heat flux case, a circular convective motion of the melted fluid takes place. The results of numerical simulations reveal declining melting rates as the mutual orientation of gravity and heat flux changes from opposite to co-directed and vice versa. The low gravity conditions delay the onset of convection-driven melting, reducing the melting rate significantly.

Solar photothermal self-deicing composite films based on fluorinated polyimide and phosphorene nanoflakes for passive anti-icing of photovoltaic panels

Snow and ice coverage greatly deteriorates the power output of photovoltaic (PV) solar cells due to sunlight obstruction and thus makes a great impact on their electricity generation. To address this problem, we design a type of passive self-deicing composite films based on colorless fluorinated polyimide as a polymeric matrix and phosphorene (PR) nanoflakes as a light absorber for the photothermal deicing of PV panels driven by solar energy. The composite films were successfully fabricated through in situ polycondensation, followed by temperature-programmed thermal imidization. The resultant composite films exhibit a colorless transparent feature along with high transmittance and high absorptivity. The presence of PR nanoflakes enhances the absorption of solar light and conversion of photothermal energy by the composite films, resulting in good photothermal self-deicing effectiveness for solar PV panels. There is an accelerated melting process occurring in the ice covering on the surface of the composite films under solar illumination. The composite film containing 2.0 wt % PR nanoflakes exhibits an optimal photothermal self-deicing performance under a high photothermal conversion efficiency of 92.9 %. The use of this composite film can promote a rapid recovery of the output voltage to an ideal value for the snow- or ice-covered PV panels through fast photothermal self-deicing. This study provides a novel approach for the development of passive self-deicing materials to enhance the power output and electricity generation efficiency of solar PV panels in the snowy and icy weather.