Computational Fluid Dynamics and Discrete Element Modelling Study of metallic powder flow characteristics in Laser Metal Deposition

Computational Fluid Dynamics and Discrete Element Modelling Study of metallic powder flow characteristics in Laser Metal Deposition
Engineering for the Information Society and Sustainable Development
Dr. Alejandro López García
The host institution is the Faculty of Engineering of the University of Deusto. The research will be carried out within the Applied Mechanics research group: https://www.deusto.es/cs/Satellite/deustoresearch/en/home/centres-teams-and-researchers/research-teams/applied-mechanics-1/equipoinvestiga?cambioidioma=si
Applied Mechanics is a young research group composed by experienced and talented researchers whose main objective is the application of the latest advances in mechanical engineering for human and societal development.
Applied Mechanics is focussed in four main research areas:
• Computational Mechanics and modelling of complex systems.
• Advanced Materials Behaviour.
• Advanced Industrial Processes.
• Transport Electrification.
The research project proposed will be related to the Computational Mechanics and modelling of complex systems, Advanced Materials Behaviour and Advanced Industrial Processes research lines.
MSc in Mechanical Engineering, Materials Science and Engineering, Chemical and Process Engineering.
Experience in numerical simulation (CFD and DEM) is not essential but it will be a plus.
Knowledge of materials behaviour, programming skills, particle technology, additive manufacturing technologies and a high level of english.
Excellent interpersonal skills, capable of working independently as well as in a team environment.
  • Chemistry (CHE)
  • Information Sciences and Engineering (ENG)
  • Physics (PHY)
Laser metal deposition (LMD) is an additive manufacturing technology based on the generation of 3D geometries by the addition of material over a substrate. A proper flow of poder will lead to a uniform and stable deposition. This flow depends on the geometry of the particles, collisions cohesion of the powder as well as laser and geometrical characteristics and carrier gas properties.

This research proposal aims to gain knowledge on the control of the mass flow rate of the powder as a means to increase process performance and quality. The final goal will be the improvement of the process to a more efficient one in terms of energy and raw material consumption, increasing, thus, its sustainability.

To achieve this, a numerical model of the flow of the powder will be developed and implemented using the discrete element method and computational fluid dynamics in order to account for the interaction of particles with the surrounding fluid. This approach will account for the three elements responsible for powder flow and process performance: powder-nozzle, carrier gas, and laser.

The model is expected to deepen the understanding process based upon the microscopical characteristics of the particles, namely: physical, chemical, and mechanical properties. Experimental characterization of the particles to calibrate the numerical model will be carried out in collaboration with Dr. Sadegh Nadimi at Newcastle University in the UK

EXCELLENCE OF THE HOST RESEARCH UNIT

López, A., Vivacqua, V., Hammond, R., Ghadiri, M., Analysis of screw feeding of faceted particles by discrete element method, Powder Technology 367 (2020), pp. 474-486, doi:10.1016/j.powtec.2020.03.064
Vivacqua, López, A., V., Hammond, R., Ghadiri, M., DEM analysis of particle shape, cohesion and strain rate on powder rheometry, Powder Technology 342 (2019), pp. 653-663, doi:10.1016/j.powtec.2018.10.034
Nan, W., Pasha, M., Bonakdar, T., López, A., Zafar, U., Nadimi, S., Ghadiri, M., Jamming during particle spreading in additive manufacturing, Powder Technology 338 (2018), pp. 253-262, doi:10.1016/j.powtec.2018.07.030
López, A., Stickland, M. T., Dempster, W. M., CFD study of fluid flow changes with erosion, Computer Physics Communications 227 (2018), pp. 27-41, doi:10.1016/j.cpc.2018.02.002
Martínez de Arenaza, I.; Hernandez, N.; Meaurio, E.; Sarasua, J.R. Competing Specific Interactions Investigated by Molecular Dynamics: Analysis of Poly(P-Dioxanone)/Poly (VinylPhenol) Blends. JOURNAL OF PHYSICAL CHEMISTRY B 2013; 117 (2), 719-724. doi:10.1021/jp310340v
A proposal (ADITFLU) was sent to the Spanish Ministry (Convocatoria 2019 Proyectos de I+D+i – RTI Tipo A) related to the current PhD topic. After evaluation, the proposal passed the threshold and it is now under evaluation by the Basque Government.
Additionally, the research group is working on the state-funded project ADDIT4ALL “Development of laser welding and laser cladding additive manufacturing as a process technology operable by VET base profiles” with funding from the Basque Government.

INTERDISCIPLINARY COLLABORATION

The proposed project is an interdisciplinary topic between the fields of mechanical and particle technology. The expertise of the researchers of the Applied Mechanics Research Team is mainly focussed in the analysis and simulation of processes and material behaviour. However, this project requires knowledge of experimental characterisation and micromechanical properties of powders. Therefore, the union of the knowledge of the University of Deusto and the University of Newcastle will give as a result a project that encompasses all aspects of the problem; from the characterisation, through the computational modelling, to the experimental validation.
Yes co-direction is envisaged. The co-director of the Thesis will be Dr. Inger Martínez de Arenaza Polancos.
The proposed project will address cross disciplinary aspects of Mechanical, Chemical and Materials Engineering as well as Physics. On one hand, the know-how on the influence of surface properties, surface energy as well as particle characterisation and the chemical properties and experiments falls under the expertise of both Dr. Inger Martínez de Arenaza Polancos (Applied Mechanics research group) and the team at the University of Newcastle led by Dr. Sadegh Nadimi. On the other hand, computational mechanics, numerical simulation and flowability of powders is the main contribution of Dr. Alejandro López and Dr. Beatriz Achiaga at the University of Deusto, within the Applied Mechanics Research Group. A third and final aspect involves the experimentation in an industrial environment and this is where the University of the Basque Country and Maddit’s expertise will be of the utmost importance, providing the field where the theories and improvements developed will be put to the test and knowledge transferred to industry.

Aligned with the 2030 Agenda, the Horizon Europe missions and goals and the Basque Country Smart Specialisation Strategy, DEUSTO research blends competitiveness, innovation and technology to tackle challenges for communities, companies and public bodies in the region. Ageing and Wellbeing; Cultural and Creative Industries and Cities; Gender; Social Justice and Inclusion and Strengthening Participation are the focus of the 5 Interdisciplinary Research Platforms. Besides, advanced research units contribute to generate knowledge and innovative solutions in the fields of efficient and clean Energy, Industry 4.0 (advanced manufacturing, data analytics…), Health and Territory.
https://www.deusto.es/cs/Satellite/deustoresearch/es/inicio/plataformas-interdisciplinares-de-investigacion

INTERNATIONAL COLLABORATION

The proposed PhD topic is clearly aligned with the 2020 agenda and the Sustainable Development Goals specifically with objectives 9 and 12.
Among the impacts marked for the projects by the H2020 program, it is worth highlighting the need to improve the efficiency, quality and reliability of the manufactured components, making a rational use of resources and raw materials that represent new business opportunities for SMEs throughout Europe. In this sense, from the H2020 program, several key lines of action are indicated such as the development of new materials (DT-NMBP-19-2019) and the development of robust industrial processes (DT-FOF-04-2018) and manufacturing high-precision measurement of large components (DT-FOF-10-2020). As far as TiC is concerned, this project will provide new and differential knowledge in terms of process control in line with the provisions of the H2020 program for quality assurance (DT-FOF-11-2020), through the digitization of associated production processes (DT-SPIRE-06-2019).
The proposed topic for PhD considers the use of TICs and advanced experimental media to improve process performance and quality. The expected result is to improve competitiveness of the industry by directing its production process towards sustainability in terms of energy and raw material consumption, as well as reducing waste disposal.
The proposal also responds to Europe’s concerns to create jobs, and it addresses energy and resource efficiency problems.
The presented proposal envisages collaboration and “co-tutelle” with one group from the University of Newcastle, providing experimental expertise in Chemical and Geotechnical Engineering and potential collaboration with a research group from the University of Leeds.
The first group is led by Dr Sadegh Nadimi, from University of Newcastle’s Geotechnical Engineering Faculty. There is an ongoing collaboration with Dr. Nadimi’s group on CFD simulation and experimentation of the behaviour of partially saturated soils.
The second group, mentioned as a potential collaborator is Ghadiri Research Group and it is based in the University of Leeds. One of the proposed Co-supervisors, Dr. Alejandro López García, is an Alumni of Ghadiri Research Group as well as a Visiting Lecturer at the University of Leeds from 2018-2019 and currently collaborating with the group.

INTERSECTORAL COLLABORATION

The research project will be co-financed by the industrial partner Maddit. This company is fully committed with the project, since the results will be applied to its process contributing to enhance its production quality, performance, and know-how. It will feed the process with priceless process experience and data, as well as testing materials and financial support. The expected finance to be given is 8000€.
In addition, collaboration with 6i Dirs Project partner institutions IK4 Azterlan in the testing of new metallic materials for Advanced Manufacturing and Bizkaia Talent will be greatly valuable during the project as well as the contributions from the industrial partner Maddit and the University of the Basque Country.

Deusto Research works closely with more than 1250 organisations (public administration, business, non-profit organisations, education and training institutions, technology centres, etc.) in areas such as health, urban development, gender, social justice and inclusion, democratic participation, regional competitiveness and energy. Since 2014 DEUSTO has been involved in 89 international research projects and worked with more than 770 partner organisations. From data collection to the implementation and piloting phases, stakeholders have an active role throughout the research project life cycle.
https://www.deusto.es/cs/Satellite/deustoresearch/es/inicio/transferencia-3/colaboracion-con-agentes-externos

IMPACT

Results of the research will include improvements that will be implemented directly in the additive manufacturing (AM) process. AM partners will profit from the generated knowledge to improve their industrial processes, making it more efficient and competitive by acting on cohesion mechanisms and enabling the possibility of using recycled powders in a very demanding industry.

Deusto Research pursues societal impact that goes beyond academia focusing on the transformation of today’s society, leading to fairer and more diverse societies, where inclusive social development and welfare are enhanced.
https://www.deusto.es/cs/Satellite/deustoresearch/en/home/dissemination-and-transfer

INNOVATION

The project proposes an innovative methodology oriented to generate valuable knowledge to be applied on the process so as to improve its performance and sustainability. The great scientific interest of the project will have a direct repercussion on the technological development of the LMD process. This is quite an ambitious challenge that can only be developed with an interdisciplinary research team composed of high level researchers.
Some of the main innovative aspects of the proposal can be summarised as follows:
-Understanding the influence of the laser heat source in the whole process and numerical simulation of the effect of laser on the circulation of gas.
-Determination of the flow characteristics in LMD processes
-Development of new testing methods to evaluate cohesion in bulk materials.
-Numerical CFD-DEM simulation of LMD process accounting for the effect of carrier gas
-Quantification of the effect of different parameters such as particle cohesion levels, carrier gas properties and mass flow rate on process performance.
-Validation of the numerical simulations at the facilities of Lortek.
These questions remain unanswered because the three aspects involved in this research; complex simulation, advanced experimental techniques, and the industrial process, have not yet been combined.

DEUSTO research internationalisation strategy pursues innovation through the participation in international research and innovation initiatives (H2020 projects, Innovation Radar)
https://www.deusto.es/cs/Satellite/deustoresearch/en/home/transfer-of-knowledge-0/innovation-radar

INCLUSION

Inclusion is an underlying principle of the 6i Dirs project. The leadership vocation of the University of Deusto goes hand in hand with its aspiration to excellence and quality and a firm commitment to social justice and inclusion. The Interdisciplinary Platform on Social Justice and Inclusion articulates interdisciplinary collaborations and channel research efforts for contributing to social justice and more inclusive and fairer societies.
https://www.deusto.es/cs/Satellite/deustoresearch/es/inicio/plataformas-interdisciplinares-de-investigacion/deusto-social-justice-and-inclusion/the-platform
Deusto recognises gender equality as a key driver for sustainable development and inclusive growth across regions, and believes that equality of academic opportunity for women is key. The Interdisciplinary Research Platform on Gender is a dynamic vehicle that teams up experts from different areas of knowledge with the dual purpose of fostering collaboration and integrating existing expertise to address society’s emerging challenges on gender issues. (https://www.deusto.es/cs/Satellite/deustoresearch/es/inicio/plataformas-interdisciplinares-de-investigacion/deusto-gender/the-university-of-deusto)
Moreover, to seek real inclusion for people with specific support needs, the 6i Dirs project ensures equal rights and opportunities with respect to access to the programme and the acquisition of the skills expected to achieve the PhD and enhance their career development and future employability. All vacancies on the Euraxess EU portal bear the Science4refugee logo to encourage refugees to apply for them. Furthermore, DEUSTO is a partner of the Scholars At Risk Network (SAR), which offers safety to scholars facing grave threats.