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This paper aims to construct smooth poly-ellipsoid shapes from synchrotron microcomputed tomography (SMT) images on sand and to develop a new discrete element method (DEM) contact detection algorithm.

Voxelated images generated by SMT on Colorado Mason sand are processed to construct smooth poly-ellipsoidal particle approximations. For DEM contact detection, cuboidal shape approximations to the poly-ellipsoids are used to speed up contact detection.

The poly-ellipsoid particle shape approximation to Colorado Mason sand grains is better than a simpler ellipsoidal approximation. The new DEM contact algorithm leads to significant speedup and accuracy is maintained.

The paper limits particle shape approximation to smooth poly-ellipsoids.

Poly-ellipsoids provide asymmetry of particle shapes as compared to ellipsoids, thus allowing closer representation of real sand grain shapes that may be angular and unsymmetric. When incorporated in a DEM for computation, the poly-ellipsoids allow better representation of particle rolling, sliding and interlocking phenomena.

Method to construct poly-ellipsoid particle shapes from SMT data on real sands and computationally efficient DEM contact detection algorithm for poly-ellipsoids.

The purpose of the paper was the application of computational fluid dynamics (CFD) techniques in fluid flow using Maxwell’s equation for partial slip modelling, estimating the flow parameters, and selecting tangential momentum accommodation coefficient (TMAC) for tight rock samples in permeability calculations.

The paper presents a numerical analysis of fluid flow in a low-porosity rock sample by using CFD. Modelling results allowed to determine mass flow rates in a rock sample and to calculate permeability values using a modified Darcy’s equation. Three-dimensional (3D) geometrical model of rock sample generated using computed X-ray tomography was used in the analysis. Steady-state calculations were carried out for defined boundary conditions in the form of pressure drop. The simulations were applied taking into account the slip phenomenon described by Maxwell’s slip model and TMAC.

Values of permeability were calculated for different values of TMAC, which vary from 0 to 1. Results in the form of gas mass flow rates were compared with the measured value of permeability for rock sample, which confirmed the high accuracy of the presented model.

Calculations of fluid flow in porous media using CFD can be used to determine rock samples’ permeability. In slip flow regime, Maxwell’s slip model can be applied and the empirical value of TMAC can be properly estimated.

This paper presents the usage of CFD, Maxwell’s equation for partial slip modelling, in fluid flow mechanism for tight rock samples. 3D geometric models were generated using created pre-processor (poROSE software) and applied in the raw form for simulation.

This study aims to evaluate and assess the elastoplastic properties of Ti-6Al-4V alloy manufactured by Arcam Q20 Plus electron beam melting (EBM) machine by a tensile test campaign and micro computerized tomography (microCT) imaging.

ASTM E8 tensile test specimens are designed and manufactured by EBM at an Arcam Q20 Plus machine. Surface quality is improved by machining to discard the effect of surface roughness. After surface machining, hot isostatic pressing (HIP) post-treatment is applied to half of the specimens to remove unsolicited internal defects. ASTM E8 tensile test campaign is carried out simultaneously with digital image correlation to acquire strain data for each sample. Finally, build direction and HIP post-treatment dependencies of elastoplastic properties are analyzed by F-test and t-test statistical analyses methods.

Modulus of elasticity presents isotropic behavior for each build direction according to F-test and t-test analysis. Yield and ultimate strengths vary according to build direction and post-treatment. Stiffness and strength properties are superior to conventional Ti-6Al-4V material; however, ductility turns out to be poor for aerospace structures compared to conventional Ti-6Al-4V alloy. In addition, micro CT images show that support structure leads to dense internal defects and pores at applied surfaces. However, HIP post-treatment diminishes those internal defects and pores thoroughly.

As a novel scientific contribution, this study investigates the effects of three orthogonal build directions on elastoplastic properties, while many studies focus on only two-build directions. Evaluation of Poisson’s ratio is the other originality of this study. Furthermore, another finding through micro CT imaging is that temporary support structures result in intense defects closer to applied surfaces; hence high-stress regions of structures should be avoided to use support structures.

This paper aims to present a methodology for the detection and categorisation of metal powder particles that are partially attached to additively manufactured lattice structures. It proposes a software algorithm to process micro computed tomography (µCT) image data, thereby providing a systematic and formal basis for the design and certification of powder bed fusion lattice structures, as is required for the certification of medical implants.

This paper details the design and development of a software algorithm for the analysis of µCT image data. The algorithm was designed to allow statistical probability of results based on key independent variables. Three data sets with a single unique parameter were input through the algorithm to allow for characterisation and analysis of like data sets.

This paper demonstrates the application of the proposed algorithm with three data sets, presenting a detailed visual rendering derived from the input image data, with the partially attached particles highlighted. Histograms for various geometric attributes are output, and a continuous trend between the three different data sets is highlighted based on the single unique parameter.

This paper presents a novel methodology for non-destructive algorithmic detection and categorisation of partially attached metal powder particles, of which no formal methods exist. This material is available to download as a part of a provided GitHub repository.