Numerical and experimental analysis of the surface energy of cohesive powders and its influence on additive manufacturing processes.

Numerical and experimental analysis of the surface energy of cohesive powders and its influence on additive manufacturing processes.
Engineering for the Information Society and Sustainable Development
Inger Martínez de arenaza Polancos
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 and Advanced Materials Behaviour research lines.
MSc in Mechanical Engineering, Materials Science and Engineering, Chemical and Process Engineering.
Experience in numerical simulation (CFD and DEM experience will be advantageous)
Knowledge of materials behaviour, programming skills, particle technology and 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)
  • Mathematics (MAT)
  • Physics (PHY)
The research project deals with the characterisation of the surface properties of the materials used in additive manufacturing (AD). One of the less known properties is surface energy. The poor flowability in powders is responsible for the increase in energy consumption, waste generation and natural resources depletion in processes involving particulate solids.
Unravelling the nature of cohesion and devising ways to characterise it accurately is one of the main challenges associated with all of the powder based manufacturing processes including AD, energy, pharmaceutical, food industries and soil mechanics in geotechnical engineering amongst many others. Proper characterisation and understanding of the phenomenon will enable running high fidelity simulations of powders to obtain reliable predictions of their behaviour. Active pharmaceutical ingredients are usually crystals which exhibit different surface energies but Molecular Dynamics Simulations do not match the experimental tests. In the AD field, accurate behaviour modelling of powders and their flowability is a demanding challenge only achievable by means of knowledge and technology. Therefore, this proposal considers using the latest advances in laboratory testing in addition to complex numerical simulations to improve our understanding of cohesion and its influence on powder flowability. The sector of application will be the AD industry being the outcomes however applicable to the rest of bulk solid based processes.

EXCELLENCE OF THE HOST RESEARCH UNIT

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
Ghadiri, M., Pasha, M., Nan, W., Hare, C., Vivacqua, V., Zafar, U., Nezamabadi, S., Lopez, A., Pasha, M., Nadimi, S., Cohesive Powder Flow: Trends and Challenges in Characterisation and Analysis, KONA Powder and Particle Journal 37 (2020), pp. 3-18, doi:10.14356/kona.2020018
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:org/10.1021/jp310340v
Martínez de Arenaza, I.; Meaurio, E.; Coto, B.; Sarasua, J.R. Molecular dynamics modelling for the analysis and prediction of miscibility in polylactide/polyvinylphenol blends. POLYMER 2010, 51(19), 4431- 4438. doi:10.1016/j.polymer.2010.07.018
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.

INTERDISCIPLINARY COLLABORATION

The proposed project is of an undoubted interdisciplinary nature, bringing together the fields of engineering, computational mechanics and mathematics, Chemical Engineering and chemistry as well as physics. These fields are all essential contributors to the current theory of cohesion and the behaviour of cohesive powders and their flowability.
The expertise of the team of the Applied Mechanics research team participating in this research line is mainly focussed on the analysis and simulation of fluid and particulate systems as well as material behaviour. However, this project requires knowledge of chemistry and physics at the microscopic level of particulates, which is the expertise offered by the collaborating group of the University of Newcastle and the University of Leeds. Therefore, combining knowledge of these groups will result in a project that encompasses all the aspects of the proposed problem; from the microscopic properties, through the mesoscopic behaviour and to the macroscopic model of the whole process. In addition to this, the collaboration with the University of the Basque Country and Maddit will enable technology transfer and application of the developed research to industry.
Yes co-direction is envisaged and it will be carried out by Dr. Alejandro López García.
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 research project deals with the characterisation of the surface properties of the materials used in additive manufacturing (AD). One of the less known properties is surface energy. The poor flowability in powders is responsible for the increase in energy consumption, waste generation and natural resources depletion in processes involving particulate solids.
Unravelling the nature of cohesion and devising ways to characterise it accurately is one of the main challenges associated with all of the powder based manufacturing processes including AD, energy, pharmaceutical, food industries and soil mechanics in geotechnical engineering amongst many others. Proper characterisation and understanding of the phenomenon will enable running high fidelity simulations of powders to obtain reliable predictions of their behaviour. Active pharmaceutical ingredients are usually crystals which exhibit different surface energies but MD simulations do not match the experimental tests. In the AD field, accurate behaviour modelling of powders and their flowability is a demanding challenge only achievable by means of knowledge and technology. Therefore, this proposal considers using the latest advances in laboratory testing in addition to complex numerical simulations to improve our understanding of cohesion and its influence on powder flowability. The sector of application will be the AD industry being the outcomes however applicable to the rest of bulk solid based processes.
The presented proposal envisages collaboration 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 AD process. Therefore, the exploitation of the project by one of the stakeholders is evident. AD 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 main innovative aspects of the present proposal include the study of the relationship between mechanical and chemical adhesion properties in different environments. Devising the relationship between measurements obtained via different types of experiments and relating them to numerical simulations will boost our understanding of cohesion. Therefore, some of the expected results include:
-Correlating surface energy measurements in IGC to Molecular Dynamics simulations and Drop test.
-Understanding the nature of cohesion, its sources and its effect on powder flowability.
-Development of new testing methods to evaluate cohesion in bulk materials.

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

-Adaption or development of new elasto-plastic-adhesive contact models for numerical Discrete Element Model Simulations.
-Successful simulation of complex powder flow processes under different conditions.
All these topics are questions that have been posed but not fully resolved yet. In particular, fidelity of numerical simulations of industrial processes will be greatly improved with accurate cohesion modelling.

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.