Pressure drop in flow across ceramic foams—A numerical and experimental study

Numerical design of open-porous titanium scaffolds for Powder Bed Fusion using Laser Beam (PBF-LB)

The paper concerns the numerical design of novel three-dimensional titanium scaffolds with complex open-porous structures and desired mechanical properties for the Powder Bed Fusion using Laser Beam (PBF-LB). The 60 structures with a broad range of porosity (38-78%), strut diameters (0.70-1.15 mm), and coefficients of pore volume variation, CV(Vp), 0.35-5.35, were designed using the Laguerre-Voronoi tessellations (LVT). Their Young's moduli and Poisson's ratios were calculated using Finite Element Model (FEM) simulations. The experimental verification was performed on the representative designs additively manufactured (AM) from commercially pure titanium (CP Ti) which, after chemical polishing, were subjected to uniaxial compression tests. Scanning Electron Microscopy (SEM) observations and microtomography (μ-CT) confirmed the removal of the support structures and unmelted powder particles. PBF-LB structures after chemical polishing were in close agreement with the CAD models' dimensions having 4-12% more volume. The computational and experimental results show that elastic properties were predicted in very close agreement for the low CV(Vp), and with even 30-40% discrepancies for CV(Vp) higher than 4.0, mainly due to PBF-LB scaffold architecture drawbacks rather than CAD inaccuracy. Our research demonstrates the possibility of designing the open-porous scaffolds with pore volume diversity and tuning their elastic properties for biomedical applications.

Simulation and Experimental of Infiltration and Solidification Process for Al2O3(3D)/5083Al Interpenetrating Phase Composite for High Speed Train Prepared by Low-Pressure Infiltration

Understanding the infiltration and solidification processes of liquid 5083Al alloy into Al2O3 three-dimensional reticulated porous ceramic (Al2O3(3D) RPC) is essential for optimizing the microstructure and properties of Al2O3(3D)/5083Al interpenetrating phase composites (IPCs) prepared by low-pressure infiltration process (LPIP). This study employs ProCAST software to simulate the infiltration and solidification processes of liquid 5083Al with pouring velocities (PV) of 0.4 m/s infiltrating into Al2O3(3D) RPC preforms with varying porosities at different pouring temperatures (PT) to prepare Al2O3(3D)/5083Al IPCs using LPIP. The results demonstrate that pore diameter of Al2O3(3D) RPC preforms and PT of liquid 5083Al significantly influence the of the infiltration. Solidification process analysis reveals that the Al2O3(3D) RPC preform with smaller pore diameters allows the lower pouring velocity of 5083Al to solidify faster compared to the preform with larger pore diameters. Al2O3(3D)/5083Al IPCs were prepared successfully from Al2O3(3D) RPC porosity of 15 PPI with liquid 5083Al at PV 0.4 m/s and PT 800 °C using LPIP, resulting in nearly fully dense composites, where both Al2O3(3D) RPCs and 5083Al interpenetrate throughout the microstructure. The infiltration and solidification defects were reduced under air pressure of 0.3 MPa (corresponding to PV of 0.4 m/s) during LPIP. Finite volume method simulations are in good agreement with experimental data, validating the suitability of the simplified model for Al2O3(3D) RPCs in the infiltration simulation.

Study and Modelling of Fluid Flow in Ceramic Foam Filters

To investigate the fluid flow characteristics of conventional Ceramic Foam Filters (CFFs) of grades 30 and 50, a 2D macro-scale geometry was generated by converting pixel grid images of the filters into vector format images. The flow behaviour through the filter channels was then numerically modelled using the Stocks equation within the Creeping Flow interface of COMSOL Multiphysics®. Through modelling, the average interstitial velocity was estimated and found to be higher than the corresponding value obtained from the Dupuit-Forchheimer equation. The discrepancy obtained suggested that the flow behaviour within the filter channels differed from that based on the simplified assumptions of the equation. The porosity and permeability of the CFFs were evaluated during the post-processing stage using surface integration and user-defined equations. The experimentally determined porosity closely matched the values obtained from the simulation model, demonstrating the reliability of the numerical approach. However, the permeability values from the simulation of CFFs of grades 30 and 50 were higher than those obtained experimentally. This discrepancy can be attributed to the larger channels in the generated geometrical pattern compared to the original CFF structure. The present findings highlight the effectiveness of the proposed methodology in developing a representative macro-scale geometry for CFFs and in simulating fluid flow behaviour.

Quantifying the Permeability Enhancement from Blast-Induced Microfractures in Porphyry Rocks Using a Cumulant Lattice Boltzmann Method

The permeability of rocks is important in a range of geoscientific applications, including $$\hbox {CO}_{2}$$ CO 2 sequestration, geothermal energy extraction, and in situ mineral recovery. This work presents an investigation of the change in permeability in porphyry rock samples due to blast-induced fracturing. Two samples were analysed before and after exposure to stress waves induced by the detonation of an explosive charge. Micro-computed tomography was used to image the interior of the samples at a pixel resolution of $$10.3\,\mu m$$ 10.3 μ m . The images were segmented into void, matrix, and grain to help quantify the differences in the rock samples. Following this, they were binarised as void or solid and the cumulant lattice Boltzmann method (LBM) was applied to simulate the flow of fluid through the connected void space. A correction required with the use of inlet and outlet reservoirs in computational permeability assessment was also proposed. Interrogation of the steady-state flow field allowed the pre- and post-loading permeability to be extracted. Conclusions were then drawn as to the effectiveness of blasting for enhancing fluid accessibility via the generation of microfractures in the rock matrix within the vicinity of a detonated charge. This paper makes contributions in three fundamental areas relating to the numerical assessment of permeability and the enhancement of fluid accessibility in low-porosity rocks. Firstly, a correction factor was proposed to account for the reservoirs commonly imposed on digitised rock samples when investigating sample permeability through numerical methods. Secondly, it validates the benefits of the LBM in handling complex geometries that would be intractable with conventional computational fluid dynamics methods that require body-fitted meshing. This is done with a novel implementation of the cumulant LBM in the open-source TCLB code. Finally, the improvement in fluid accessibility in low-permeability rock samples was shown through the assessment of multiple regions within two blasted samples. It was found that the blast-induced loading can generate extended microfractures that results in multiple orders of magnitude of permeability enhancement if the target rock possesses existing weaknesses and/or mineralisation.

Elastic Properties of Open Cell Metallic Foams-Modeling of Pore Size Variation Effect

Elastic properties of open-cell metallic foams are investigated in correlation with relative density and pore size variation. A variety of foam architectures, with open porosity above 70% (relative density below 0.30) and various pore size distributions, were modeled using Laguerre-Voronoi tessellations (LVT). The coefficient of pore volume variation, CV(V), was introduced to quantify the uniformity of designed structures and ranged between 0.5 to 2.1. Elastic behavior of the modeled foams to uniaxial compression along three orthogonal directions was analyzed using the finite element (FE) method. It is shown that Young's modulus and Poisson's ratio of open-cell metals is not solely a function of relative density (porosity) but the pore size variation as well. For similar porosity (approx. 74-98%), Young's modulus and Poisson's ratio may be reduced by approx. 25-30% and 10-25%, respectively, when CV(V) increases from 0.5 to 2.1. Furthermore, the incorporation of a relationship between Young's modulus and the coefficient of pore volume variation to the Gibson-Ashby model is proposed.

Study on flow resistance characteristics of SiC foam ceramics

Porous media combustion has significant advantages of high thermal efficiency and low pollution emissions. However, the flow state in the porous media will affect the reaction rate. In order to increase the rate of chemical reactions, the fluid flow resistance in the porous media must be reduced. The pressure drop test of SiC foam ceramics was carried out. By changing the pore density of the experimental materials, the pressure drop characteristics of SiC foam ceramic are tested and analyzed. Based on the classical Ergun equation, a semi-empirical formula for calculating the pressure drop gradient of SiC foam ceramics with the airflow velocity is proposed. The two constants in the formula are calculated by measurement, and the applicability of the formula is verified. This formula can quickly analyze the pressure drop characteristics of SiC foam ceramic materials. The accurate measurement of pressure drop is helpful to determine the rated pressure of the head of foam ceramic burner and reduce the investment of front-end fans in industrial burners.

CFD Simulations of Radiative Heat Transport in Open-Cell Foam Catalytic Reactors

The heat transport management in catalytic reactors is crucial for the overall reactor performance. For small-scale dynamically-operated reactors, open-cell foams have shown advantageous heat transport characteristics over conventional pellet catalyst carriers. To design efficient and safe foam reactors as well as to deploy reliable engineering models, a thorough understanding of the three heat transport mechanisms, i.e., conduction, convection, and thermal radiation, is needed. Whereas conduction and convection have been studied extensively, the contribution of thermal radiation to the overall heat transport in open-cell foam reactors requires further investigation. In this study, we simulated a conjugate heat transfer case of a µCT based foam reactor using OpenFOAM and verified the model against a commercial computational fluid dynamics (CFD) code (STAR-CCM+). We further explicitly quantified the deviation made when radiation is not considered. We studied the effect of the solid thermal conductivity, the superficial velocity and surface emissivities in ranges that are relevant for heterogeneous catalysis applications (solid thermal conductivities 1–200 W m−1 K−1; superficial velocities 0.1–0.5 m s−1; surface emissivities 0.1–1). Moreover, the temperature levels correspond to a range of exo- and endothermal reactions, such as CO2 methanation, dry reforming of methane, and methane steam reforming. We found a significant influence of radiation on heat flows (deviations up to 24%) and temperature increases (deviations up to 400 K) for elevated temperature levels, low superficial velocities, low solid thermal conductivities and high surface emissivities.

Influence of Pore Size Variation on Thermal Conductivity of Open-Porous Foams

This study addresses the influence of pore size variation on the effective thermal conductivity of open-cell foam structures. Numerical design procedure which renders it possible to control chosen structural parameters has been developed based on characterization of commercially available open-cell copper foams. Open-porous materials with various pore size distribution were numerically designed using the Laguerre–Voronoi Tessellations procedure. Heat transfer through an isolated structure was simulated with the finite element method. The results reveal that thermal conductivity is strongly related to porosity, which is in agreement with the literature. The influence of pore size distribution has also been observed and compared with analytical formulas proposed in the literature.