Graduate Thesis Or Dissertation
 

Process Physics, Strategies and Economics in Metal Additive Manufacturing and Digital Microstructural Control for Energy and Chemical Process Components

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https://ir.library.oregonstate.edu/concern/graduate_thesis_or_dissertations/hd76s760r

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  • Advances in plant construction within the energy and chemical process industries require inexpensive process intensification (PI) technology as a means to reduce plant size for enabling modular construction. One form of PI is microchannel process technology where arrays of microchannels, having hydraulic diameters on the order of 0.1 to 1 mm, are used to accelerate heat and mass transfer within process equipment due to shorter diffusional distances and higher surface-area-to-volume ratios. In this dissertation, metal additive manufacturing (MAM) processes capable of producing complex geometries out of multiple materials are used to investigate the fabrication of two PI components. The geometric capability of a binder jet (BJ) MAM process is investigated to produce an economically viable micro-scale liquid-liquid extractor and multi-phase separator in Chapter 2. A manufacturing process design methodology was used to evaluate both photochemical machining and BJ as a means for producing the micro-post arrays within the separator. Cost curves show that for a 0.3 mm deep micro-post array, photochemical machining was found to be much cheaper than BJ. However, because BJ processes enable micro-posts with more than 13 times higher depth-to-width aspect ratios, BJ was found to decrease the overall cost of the extractor/separator by more than 50% for a 500 barrel per day plant, with breakeven as low as 15 barrels per day. These economics were validated by building extractor/separator plates and characterizing them dimensionally and functionally. In Chapters 3 and 4, a multi-material laser directed energy deposition (LDED) MAM process is investigated to advance a heat exchanger application. Inconel 625 – GRCop-42 bimetallic joints were needed to support the anisotropic flow of heat within a heat exchanger application. GRCop-42 has a high thermal conductivity of 330 W/mK at 800 °C, which is about 13 times higher than Inconel 625 at this temperature. By deploying GRCop-42 posts within heat exchanger channels adjacent to Inconel 625 fins, entropic losses within the heat exchanger are minimized by maximizing the flow of heat between channels. Based on a review of the literature, two approaches were investigated for eliminating failure mechanisms at the interface between Cu-alloy-based pins and the Ni-alloy-based fins. First, a compositionally graded metal (CGM) was explored for reducing the differences in thermophysical properties between the two parent alloys. Second, a discrete transition joint was investigated using parameters to minimize mechanical mixing, epitaxial grain growth, and residual stress across the interface. In Chapter 3, the process-microstructure relationship of an Inconel 625/GRCop 42 CGM produced “on-the-fly” was investigated using a simultaneous wire-fed/powder-fed LDED process. New knowledge learned from the process-microstructure relationship in single-track and multi-track specimens is used to produce a crack-free Inconel 625/GRCop 42 CGM. In Chapter 4, the process physics at the interface of an Inconel 625 – GRCop-42 bi-metallic discrete joint produced using LDED is investigated as a means to inform process strategies for producing crack-free bimetal joints. The process physics at the interface for dilution, epitaxial grain growth, and crack formation and propagation were used to develop a process strategy for producing a crack-free Inconel 625-GRCop-42 discrete joint.
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  • Pending Publication
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  • 2023-03-24 to 2024-04-24

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file details SriramManoharan2023.pdf 2023-03-27 Público Baixar