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This paper aims to anticipate the possible development direction of WAAM. For large-scale and complex components, the material loss and cycle time of wire arc additive manufacturing (WAAM) are lower than those of conventional manufacturing. However, the high-precision WAAM currently requires longer cycle times for correcting dimensional errors. Therefore, new technologies need to be developed to achieve high-precision and high-efficiency WAAM.

This paper analyses the innovations in high-precision WAAM in the past five years from a mechanistic point of view.

Controlling heat to improve precision is an effective method. Methods of heat control include reducing the amount of heat entering the deposited interlayer or transferring the accumulated heat out of the interlayer in time. Based on this, an effective and highly precise WAAM is achievable in combination with multi-scale sensors and a complete expert system.

Therefore, a development direction for intelligent WAAM is proposed. Using the optimised process parameters based on machine learning, adjusting the parameters according to the sensors’ in-process feedback, achieving heat control and high precision manufacturing.

The aims of this study is to numerically investigate the thermal phenomena during magnetohydrodynamic (MHD) free convection in an oblique enclosure filled with porous media saturated with Cu–Al₂O₃/water hybrid nanofluid and heated at the left wavy wall. The thermophysical phenomena are explored thoroughly by varying the amplitude (λ) and undulation (n) of the wavy wall and the inclination of the enclosure (γ) along with other pertinent physical parameters. Darcy–Rayleigh number (Ra_m), Darcy number (Da), Hartmann number (Ha) and nanoparticle volumetric fraction (ϕ). The effect of all parameters has been analyzed and represented by using heatlines, isotherms, streamlines, average Nusselt number and local Nusselt number.

The finite volume method is used to work out the transport equations coupled with velocity, pressure and temperature subjected to non-uniform staggered grid structure after grid-sensitivity analysis by an indigenous computing code and the semi-implicit method for pressure linked equations (SIMPLE) algorithm. The solution process is initiated following an iterative approach through the alternate direction implicit sweep technique and the tridiagonal matrix algorithm (TDMA) algorithm. The iterative process is continued until successive minimization of the residuals (<1e-8) for the governing equations.

This study reveals that the increase in the heating surface area does not always favor heat transfer. An increase in the undulation amplitude enhances the heat transfer; however, there is an optimum value of undulation of the wavy wall for this. The heat transfer enhancement because of the wall curvature is revealed at higher Ra_m, lower Da and Ha and lower volume fraction of nanoparticles. In general, this augmentation is optimum for four undulations of the wavy wall with an amplitude of λ = 0.3. The heat transfer enhancement can be more at the cavity inclination   γ = 45°.

The technique of this investigation could be used in other multiphysical areas involving partial porous layers, conducting objects, different heating conditions, wall motion, etc.

This study is to address MHD thermo-fluid phenomena of Cu–Al₂O₃/water-based hybrid nanofluid flow through a non-Darcian porous wavy cavity at different inclinations. The amplitude and number of undulations of the wavy wall, permeability of the porous medium, magnetic field intensity, nanoparticle volumetric fraction and inclinations of the enclosure play a significant role in the heat transfer process. This analysis and the findings of this work can be useful for the design and control of similar thermal systems/devices.

Many researchers have examined the problem of buoyancy-induced free convection in a wavy-porous cavity packed with regular fluids or nanofluids. However, the effect of magnetic fields along with the amplitude (λ) at different undulations (n) of the heated wavy wall of an inclined enclosure is not attended so far to understand the transport mechanisms. Most often, the evolutions of the thermo-fluid phenomena in such complex geometries invoking different multiphysics are very intricate. Numerical implementations for simulations and subsequent post-processing of the results are also challenging.

This study aims to numerically examine the influence of various geometric parameters of a novel W-shaped porous cavity undergoing hybrid nanofluid-based magnetohydrodynamic mixed convection. The W-shaped cavity is modified from the classical trapezoidal cavity by constructing a triangular shape at its bottom. This cavity is isothermally active at the bottom, with different numbers and heights of the triangular peak (or undulation). The heated hybrid nanofluid (Cu–Al₂O₃–H₂O) flow is cooled through the translating top wall. Inclined sidewalls are thermally insulated. To compare the impacts of change in geometric parameters, a square cavity under similar boundary conditions is also simulated. This study is carried out systematically addressing the various influences from a range of parameters like side angles (γ), number (m) and height (λ) of the bottom undulation, Reynolds number (Re), Richardson number (Ri), Darcy number (Da), Hartmann number (Ha), hybrid nanoparticles volume fraction (φ) on the overall thermal performance of the cavity.

Applying the finite volume approach, the transport equations involving multiphysical conditions like porous substance, hybrid nanofluid, magnetic field and shearing force are solved numerically by using a written FORTRAN-based code following the SIMPLE algorithm. The algebraic equations are solved over all the control volumes in an iterative process using the alternate direction implicit scheme and the tri-diagonal matrix algorithm. The converged solution of the iterative process is obtained when the relative error levels satisfy the convergence criterion of 10^–8 and 10^–10 for the maximum residuals and the mass defect, respectively.

It is revealed that an increase in the bottom undulation height always improves the thermal energy transfer despite the reduction of fluid volume. Thermal energy transfer significantly depends on the heating and cooling surface lengths, fluid volume in the cavity and the magnitude of the bottom undulation height of the W-shaped cavity. With the increase in bottom undulation height, effective heating length increases by ∼28%, which leads to a ∼15% reduction in the effective volume of the working fluid and a gain in heat transfer by ∼56.48%. In general, the overall thermal energy transport is improved by increasing Re, Ri and Da; whereas it is suppressed by increasing Ha.

There are many opportunities for future research experimentally or numerically, considering different curvature effects, orientations of the geometry, working fluids, boundary conditions, etc. Furthermore, this study could be extended by considering unsteady flow or turbulent flow.

In many modern systems/processes pertaining to materials processing, continuous casting, food processing, chemical reactors, biomedical applications, etc. fine control in the transport process is a major concern. The findings of this analysis can effectively be useful for other applications for getting more control features in terms of achieving the operational objectives. The approach of the system analysis (considering geometrical size parameters to delve into the underlying transport physics) and the obtained simulated results presented in the work can usefully be applicable to similar thermal systems/devices such as materials processing, thermal mixing, chemical reactors, heat exchangers, etc.

From the well-documented and vast pool of literature survey, it is understood that there exists no such investigation on the considered geometry and study. This study contributes a lot to understanding magnetic field moderated thermofluid flow of a hybrid nanofluid in a porous medium filled W-shaped cavity, in consideration of different geometrical shape parameters (undulation peak numbers at bottom wall, peak heights, side angles and heating and cooling length). Findings brought by this study provide great insights into the design and operation under various ranges of multiphysical thermofluid-flow processing phenomena.

This paper aims to present a numerical study that investigates the flow of MgO-Al₂O₃/water hybrid nanofluid inside a porous elliptical-shaped cavity, in which we aim to examine the performance of this thermal system when exposed to a magnetic field via heat transfer features and entropy generation.

The configuration consists of the hybrid nanofluid out layered by a cold ellipse while it surrounds a non-square heated obstacle; the thermal structure is under the influence of a horizontal magnetic field. This problem is implemented in COMSOL multiphysics, which solves the related equations described by the “Darcy-Forchheimer-Brinkman” model through the finite element method.

The results illustrated as streamlines, isotherms and average Nusselt number, along with the entropy production, are given as functions of: the volume fraction, and shape factor to assess the behaviour of the properties of the nanoparticles. Darcy number and porosity to designate the impact of the porous features of the enclosure, and finally the strength of the magnetic induction described as Hartmann number. The outcomes show the increased pattern of the thermal and dynamical behaviour of the hybrid nanofluid when augmenting the concentration, shape factor, porosity and Darcy number; however, it also engenders increased formations of irreversibilities in the system that were revealed to enhance with the permeability and the great properties of the nanofluid. Nevertheless, this thermal enhanced pattern is shown to degrade with strong Hartmann values, which also reduced both thermal and viscous entropies. Therefore, it is advised to minimize the magnetic influence to promote better heat exchange.

The investigation of irreversibilities in nanofluids heat transfer is an important topic of research with practical implications for the design and optimization of heat transfer systems. The study’s findings can help improve the performance and efficiency of these systems, as well as contribute to the development of sustainable energy technologies. The study also offers an intriguing approach that evaluates entropy growth in this unusual configuration with several parameters, which has the potential to transform our understanding of complicated fluid dynamics and thermodynamic processes, and at the end obtain the best thermal configuration possible.

This study aims to investigate the impact of different heater geometries (flat, rectangular, semi-elliptical and triangular) on hybrid nanofluidic (Cu–Al₂O₃–H₂O) convection in novel umbrella-shaped porous thermal systems. The system is top-cooled, and the identical heater surfaces are provided centrally at the bottom to identify the most enhanced configuration.

The thermal-fluid flow analysis is performed using a finite volume-based indigenous code, solving the nonlinear coupled transport equations with the Darcy number (10^–5 ≤ Da ≤ 10^–1), modified Rayleigh number (10 ≤ Ra_m ≤ 10⁴) and Hartmann number (0 ≤ Ha ≤ 70) as the dimensionless operating parameters. The semi-implicit method for pressure linked equations algorithm is used to solve the discretized transport equations over staggered nonuniform meshes.

The study demonstrates that altering the heater surface geometry improves heat transfer by up to 224% compared with a flat surface configuration. The triangular-shaped heating surface is the most effective in enhancing both heat transfer and flow strength. In general, flow strength and heat transfer increase with rising Ra_m and decrease with increasing Da and Ha. The study also proposes a mathematical correlation to predict thermal characteristics by integrating all geometric and flow control variables.

The present concept can be extended to further explore thermal performance with different curvature effects, orientations, boundary conditions, etc., numerically or experimentally.

The present geometry configurations can be applied in various engineering applications such as heat exchangers, crystallization, micro-electronic devices, energy storage systems, mixing processes, food processing and different biomedical systems (blood flow control, cancer treatment, medical equipment, targeted drug delivery, etc.).

This investigation contributes by exploring the effect of various geometric shapes of the heated bottom on the hydromagnetic convection of Cu–Al₂O₃–H₂O hybrid nanofluid flow in a complex umbrella-shaped porous thermal system involving curved surfaces and multiphysical conditions.

This paper aims to present a novel hybrid time integration approach for efficient numerical simulations of multiscale problems involving interactions of electromagnetic fields with fine structures.

The entire computational domain is discretized with a coarse grid and a locally refined subgrid containing the tiny objects. On the coarse grid, the time integration of Maxwell’s equations is realized by the conventional finite-difference technique, while on the subgrid, the unconditionally stable Krylov-subspace-exponential method is adopted to breakthrough the Courant–Friedrichs–Lewy stability condition.

It is shown that in contrast with the conventional finite-difference time-domain method, the proposed approach significantly reduces the memory costs and computation time while providing comparative results.

An efficient hybrid time integration approach for numerical simulations of multiscale electromagnetic problems is presented.

A model of hybrid fillet welding is built and solved. No additional material (welding rod, etc.) is used. Heating of the welded parts is realized by laser beam with induction preheating and/or postheating. The purpose of these operations is to reduce the temperature gradient in welded parts in the course of both heating and cooling, which reduces the resultant hardness of the weld and its neighborhood and also reduces undesirable internal mechanical strains and stresses in material.

The complete mathematical model of the combined welding process is presented, taking into account all relevant nonlinearities. The model is then solved numerically by the finite element method. The methodology is illustrated with an example, the results of which are compared with experiment.

The proposed model provided satisfactory results even when some subtle phenomena were not taken into account (flow of melt in the pool after irradiation of the laser beam driven by the buoyancy and gravitational forces and evaporation of molten metal and influence of plasma cloud above the irradiated spot).

Accuracy of the results depends on the accuracy of physical parameters of materials entering the model and their temperature dependencies. These quantities are functions of chemical composition of the materials used, and may more or less differ from the values delivered by manufacturers. Also, the above subtle physical phenomena exhibit stochastic character and their modeling may be accompanied by non-negligible uncertainties.

The presented model and methodology of its solution may represent a basis for design of welding processes in various branches of industry.

The model of a complex multiphysics problem (induction-assisted laser welding) provides reasonable results confirmed by experiments.

The purpose of this study is to address magnetohydrodynamic (MHD) bioconvection caused by the swimming of oxytactic microorganisms in a linearly heated square cavity filled with porous media and Cu–water nanofluid. The effects of different multiphysical aspects are demonstrated using local distributions as well as global quantities for fluid flow, temperature, oxygen concentration and microorganisms population.

The coupled transport equations are converted into the nondimensional partial differential equations, which are solved numerically using a finite volume-based computing code. The flow of Cu–water nanofluid through the pores of porous media is formulated following the Brinkman–Forchheimer–Darcy model. The swimming of oxytactic microorganisms is handled following a continuum model.

The analysis of transport phenomena of bioconvection is performed in a linearly heated porous enclosure containing Cu–water nanofluid and oxytactic microorganisms under the influence of magnetic fields. The application of such a system could have potential impacts in diverse fields of engineering and science. The results show that the flow and temperature distribution along with the isoconcentrations of oxygen and microorganisms is markedly affected by the involved governing parameters.

Similar study of bioconvection could be extended further considering thermal radiation, chemical attraction, gravity and light.

The outcomes of this investigation could be used in diverse fields of multiphysical applications, such as in food industries, chemical processing equipment, fuel cell technology and enhanced oil recovery.

The insight of the linear heating profile reveals a special attribute of simultaneous heating and cooling zones along the heated side. With such an interesting feature, the MHD bioconvection of oxytactic microorganisms in nanofluid-filled porous substance is not reported so far.

The purpose of this study is to carry out a comprehensive analysis of magneto-hydrodynamics (MHD), nanofluidic flow dynamics and heat transfer as well as thermodynamic irreversibility, within a novel butterfly-shaped cavity. Gaining a thorough understanding of these phenomena will help to facilitate the design and optimization of thermal systems with complex geometries under magnetic fields in diverse applications.

To achieve the objective, the finite element method is used to solve the governing equations of the problem. The effects of various controlling parameters such as butterfly-shaped triangle vertex angle (T), Rayleigh number (Ra), Hartmann number (Ha) and magnetic field inclination angle (γ ) on the hydrothermal performance are analyzed meticulously. By investigating the effects of these parameters, the authors contribute to the existing knowledge by shedding light on their influence on heat and fluid transport within butterfly-shaped cavities.

The major findings of this study reveal that the geometrical shape significantly alters fluid motion, heat transfer and irreversibility production. Maximum heat transfer, as well as entropy generation, occurs when the Rayleigh number reaches its maximum, the Hartmann number is minimized and the angle of the magnetic field is set to 30° or 150°, while the butterfly wings angle or vertex angle is kept at a maximum of 120°. The intensity of the magnetic field significantly controls the heat flow dynamics, with higher magnetic field strength causing a reduction in the flow strength as well as heat transfer. This configuration optimizes the heat transfer characteristics in the system.

Further research can be expanded on this study by examining thermal performance under different curvature effects, orientations, boundary conditions and additional factors. This can be accomplished through numerical simulations or experimental investigations under various multiphysical scenarios.

The geometric configurations explored in this research have practical applications in various engineering fields, including heat exchangers, crystallization processes, microelectronic devices, energy storage systems, mixing processes, food processing, air-conditioning, filtration and more.

This study brings value by exploring a novel geometric configuration comprising the nanofluidic flow, and MHD effect, providing insights and potential innovations in the field of thermal fluid dynamics. The findings contribute a lot toward maximizing thermal performance in diverse fields of applications. The comparison of different hydrothermal behavior and thermodynamic entropy production under the varying geometric configuration adds novelty to this study.

The purpose of this paper is to propose a physics-aware algorithm to obtain radio frequency (RF)-reduced models of micro-electromechanical systems (MEMS) switches and show how, together with multiphysics macromodels, they can be realized as circuits that include both lumped and distributed parameters.

The macromodels are extracted with a robust procedure from the solution of Maxwell’s equations with electromagnetic circuit element (ECE) boundary conditions. The reduced model is extracted from the simulations of three electromagnetic field problems, in full-wave regime, that correspond to three configurations: signal lines alone, switch in the up and down positions.

The technique is exemplified for shunt switches, but it can be extended for lateral switches. Moreover, the algorithm is able take frequency dependence into account both for the signal lines and for the switch model. For the later, the order of the model is increased until a specified accuracy is achieved.

The use of ECE as boundary conditions for the RF simulation of MEMS switches has the advantage that the definition of ports is unambiguous and robust as the ports are clearly defined. The extraction approach has the advantage that the simplified model keeps the basic phenomena, i.e. the propagation of the signal along the lines. As the macromodel is realized with a netlist that uses transmission lines models, the lines’ extension is natural. The frequency dependence can be included in the model, if needed.