Michael Alexander Benedict

Experimental study of the maximum resolution and packing density achievable in sintered and non-sintered binder-jet 3D printed steel microchannels

Developing high-resolution 3D printed metallic microchannels is a challenge especially when there is an essential need for high packing density of the primary metal. While high packing density could be achieved by heating the structure to the sintering temperature, some heat sensitive applications require other strategies to improve the packing density of primary metal. In this study the goal is to develop microchannels with high green (bound) or pack densities on the scale of 100–300 microns which have a robust mechanical structure. Binder-jet 3D printing is an additive manufacturing process in which droplets of binder are deposited via inkjet into a bed of powder. By repeatedly spreading thin layers of powder and depositing binder into the appropriate 2D profiles, complex 3D objects can be created one layer at time. Microchannels with features on the order of 500 microns were fabricated via binder jetting of steel powder and then sintered and/or infiltrated with a secondary material. The droplet volume of the inkjet-deposited binder was varied along with the print orientation. The resolution of the process, the subsequent features sizes of the microchannels, and the overall microchannel quality were studied as a function of droplet volume, orientation, and infiltration level.Copyright

Thermofluid Analysis of the Magnetocaloric Refrigeration

While there have been extensive studies on thermofluid characteristics of different magnetocaloric refrigeration systems, a conclusive optimization study using non-dimensional parameters which can be applied to a generic system has not been reported yet. In this study, a numerical model has been developed for optimization of active magnetic refrigerator (AMR). This model is computationally efficient and robust, making it appropriate for running the thousands of simulations required for parametric study and optimization. The governing equations have been non-dimensionalized and numerically solved using finite difference method. A parametric study on a wide range of non-dimensional numbers has been performed. While the goal of AMR systems is to improve the performance of competitive parameters including COP, cooling capacity and temperature span, new parameters called “AMR performance index-1” have been introduced in order to perform multi objective optimization and simultaneously exploit all these parameters. The multi-objective optimization is carried out for a wide range of the non-dimensional parameters. The results of this study will provide general guidelines for designing high performance AMR systems.Copyright