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Title: Multiphase hydrodynamic flow characterization for surface finishing the laser powder bed fused AlSi10Mg conformal cooling channels
Authors: Nagalingam, Arun Prasanth
Santhanam, Vijay
Dachepally, Nithin Kumar Gupta
Yeo, Swee Hock
Keywords: Engineering::Manufacturing
Issue Date: 2021
Source: Nagalingam, A. P., Santhanam, V., Dachepally, N. K. G. & Yeo, S. H. (2021). Multiphase hydrodynamic flow characterization for surface finishing the laser powder bed fused AlSi10Mg conformal cooling channels. Journal of Manufacturing Processes, 68(Part A), 277-292.
Journal: Journal of Manufacturing Processes 
Abstract: Surface finishing additive manufactured internal passages using dynamic cavitation-assisted microparticle flow is becoming popular. The nucleation, growth, and collapse of the cavitation inside complex passages are crucial contributors for surface finishing and call for understanding for process improvement. In this work, we aimed to surface finish linear Direct Metal Laser Sintered (DMLS) AlSi10Mg conformal cooling channels (CCC). First, we surface finished the cooling channels with a square cross-section of width varying from 5 mm to 1 mm and length extending up to 50 mm using various multiphase finishing modes. Second, we characterized the multiphase flow with a high-speed camera and underwater hydrophone measurements, focusing on the cavitation effects, inside the cooling channels. Third, we performed numerical simulations and extracted cavitation and turbulent kinetic energy distributions inside the channels. The surface texture results were supported by cavitation frequency (nfo), root mean square pressure (Prms), and acoustic energy (EA) observations from the hydrophone. Finally, we explained the surface finishing trend by varying the channel size and length using numerical simulation results. The results suggest that the cavitation phase distribution decrease with a decrease in channel size and an increase in the channel length. The method proposed is useful in establishing appropriate process parameters to achieve a uniform surface finish along the entire channel length.
ISSN: 1526-6125
DOI: 10.1016/j.jmapro.2021.05.040
Rights: © 2021 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
Fulltext Permission: none
Fulltext Availability: No Fulltext
Appears in Collections:MAE Journal Articles

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