Development of a Novel Water Jet Polisher Using Soft Abrasives for Small Complex-Structure Heat Pipes of Aluminum Alloy Produced Using Additive Manufacturing
Abstract
:1. Introduction
2. Experimental Preparation
2.1. Additive Manufacturing of Heat Pipes
2.2. Experimental Equipment and Operation
2.3. CFD Simulation
3. Results and Discussion
3.1. Commercial SiO2 Abrasive Particles for the Erosion Effects and Analysis of High-Pressure Water Jets
3.2. Plastic Abrasive Particles Are Used for the Treatment Effect and Analysis of High-Pressure Water Jets
3.3. CFD Mechanism Explanation and Analysis
4. Conclusions
- The SiO2 abrasive can effectively remove both satellites and balling defects, but will lead to corner erosion and the heat pipe leaking rapidly. For a 15° and 30° heat pipe, the leaking time is 15–30 s and 10–20 s, respectively, showing that the SiO2 abrasive is not suitable for cleaning bent heat pipes.
- Simulation revealed that the reacceleration of the abrasive is key to the cleaning process. Further analysis found that the erosion caused by the SiO2 abrasive particles will be enhanced with the increase in the bent angle or in the abrasive particle size. At a 30° angle, the erosion rate is more concentrated at the corner, with a higher peak, resulting in a shorter leakage time.
- The erosion rate of the SiO2 abrasive particles is 17 times higher than that of the PMMA abrasive particles, and the peak value of the momentum loss in the jet direction is more than 2 times higher. Second, the strength of PMMA in terms of physical properties such as density and hardness is much lower than that of the SiO2 abrasive particles, which, combined with its relatively homogeneous and rounded abrasive shape, makes it well suited for handling the microstructure of additively manufactured heat pipes.
- The PMMA abrasive effectively eliminates satellites, and the removal efficiency of PMMA-#200 on the satellites is close to complete. The surface quality Sa of the straight heat pipe was increased from 3.410 μm to 0.989 μm after the PMMA-#200 abrasive treatment.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Appendix A
Level 0 | Level 1 | Level 2 | |
---|---|---|---|
Factor A (Types of abrasive) | SiO2 | PMMA | PS |
Factor B (Size of abrasive) | #200 | #400 | #600 |
Factor C (Angle of heat pipe) | 0° | 15° | 30° |
Factor C | ||||
---|---|---|---|---|
Factor A | Factor B | 0 | 1 | 2 |
0 | 0 | 000 | 001 | 002 |
0 | 1 | 010 | 011 | 012 |
0 | 2 | 020 | 021 | 022 |
1 | 0 | 100 | 101 | 102 |
1 | 1 | 110 | 111 | 112 |
1 | 2 | 120 | 121 | 122 |
2 | 0 | 200 | 201 | 202 |
2 | 1 | 210 | 211 | 212 |
2 | 2 | 220 | 221 | 222 |
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Process Parameters | Specific Content |
---|---|
Laser power | 135 W |
Spot size | 70 μm |
Scan speed | 900 mm/s |
Line spacing | 0.12 mm |
Layer thickness | 0.03 mm |
Name | Specific Content |
---|---|
Jet pressure | 30 MPa |
Flow rate of water | 15 L/min |
Concentration of abrasive | 1.5 wt.% |
Size of abrasive | #200, #400, #600 |
Types of abrasive | SiO2, PMMA, PS |
SiO2 | PMMA | PS | |
---|---|---|---|
Density (g/cm3) | 2.2 | 1.2 | 1.05 |
Mohs Hardness | 7.0 | 2–2.5 | 2 |
Hygroscopicity | 0 | 0.4% | 0.02% |
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Zhang, T.; Zhang, Z.; Feng, J.; Shi, C.; Zhou, H.; Meng, F.; Tong, D. Development of a Novel Water Jet Polisher Using Soft Abrasives for Small Complex-Structure Heat Pipes of Aluminum Alloy Produced Using Additive Manufacturing. Materials 2024, 17, 582. https://doi.org/10.3390/ma17030582
Zhang T, Zhang Z, Feng J, Shi C, Zhou H, Meng F, Tong D. Development of a Novel Water Jet Polisher Using Soft Abrasives for Small Complex-Structure Heat Pipes of Aluminum Alloy Produced Using Additive Manufacturing. Materials. 2024; 17(3):582. https://doi.org/10.3390/ma17030582
Chicago/Turabian StyleZhang, Tianyu, Zhenyu Zhang, Junyuan Feng, Chunjing Shi, Hongxiu Zhou, Fanning Meng, and Dingyi Tong. 2024. "Development of a Novel Water Jet Polisher Using Soft Abrasives for Small Complex-Structure Heat Pipes of Aluminum Alloy Produced Using Additive Manufacturing" Materials 17, no. 3: 582. https://doi.org/10.3390/ma17030582