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This paper aims to propose a method for automatic design of additive manufacturing (AM) flow channel paths driven by path length and pressure loss. The research focuses on the automatic design of channel paths, intending to achieve the shortest flow channel length or minimum pressure loss and improve the design efficiency of AM parts.

The initial layout of the flow channels is redesigned to consider the channels print supports. Boundary conditions and constraints are defined according to the redesigned channels layout, and the equation consisting of channel length and pressure loss is used as the objective function. Then the path planning simulation is performed based on particle swarm algorithm. The proposed method describes the path of flow channels using spline cures. The spline curve is controlled by particle (one particle represents a path), and the particle is randomly generated within the design space. After the path planning simulation is completed, the generated paths are used to create 3D parts.

Case study 1 demonstrates the automatic design of hydraulic spool valve. Compared to conventional spool valve, the pressure loss was reduced by 86% and the mass was reduced by 83%. The design results of case study 2 indicate that this approach is able to find the shortest channel path with lower computational cost.

The automatic design method of flow channel paths driven by path length and pressure loss presented in this paper provides a novel solution for the creation of AM flow components.

The filterable particles found in electronic solder fluxes vary considerably in both concentration and chemistry. Four fluxes from three manufacturers were examined, including both rosin fluxes and mildly activated resin fluxes. Individual particles were examined by optical light microscopy (OLM) and scanning electron microscopy/energy dispersive X‐ray spectroscopy (SEM/EDX). Finally, an automated SEM/EDX system was used to collect and summarise information about the size and chemistry of a hundred or more particles from each flux. The number of particles per microgram of flux was found to vary by two orders of magnitude (0.004 to 0.4 per μg). The particle diameters ranged from 0.2–20 μm with averages of 1–3 μm. A large fraction of the particles (33–75% by number) were organic substances not soluble in the flux. The bulk of the inorganic particles were composed of sulphates, silicates and metal oxides. Thus, some solder fluxes may be introducing several contaminant particles into each solder contact. These contaminants may affect the quality of the solder joint depending on particle size and composition.

The purpose of this paper is to develop a cyclone with an internal electric field to capture dust and fine carbon particles with less than 5 μm diameter.

The cyclone collection efficiency model described by Cooper and Alley was used to design a conventional cyclone, which was later modified by introduction of the solenoid around it to introduce an electric field. The cyclone design performance was later established using ferrosilicon powder with less than 5 μm diameter.

The cyclone was found to have a particle collection efficiency of around 25 per cent for ferrosilicon powder before the introduction of the solenoid; the introduction of the solenoid increased the particle collection efficiency to around 50 per cent and the charging of the solenoid further increased the collection efficiency to 85 per cent at 2 kV DC and 97 per cent at 3 kV DC. When the cyclone was placed back on the gasifier system and supplied with 2 kV DC, it collected up to 270 g of fine carbon particles within 150 min of operation.

The major drawback was that the highest particle collection efficiency for the cyclone could only be achieved at very high voltage (3 kV) but this could not be supplied when the cyclone was back in the gasifier system due to air ionization that results in the corona effect.

The collection of very fine particles (less than 5 μm diameter) in hot gas streams is always a challenge, particularly in biomass gasifier systems. This resulted in a high cost of gas purification or initial investments in downstream processes. The developed cyclone could cut down this expenditure since most of the particles will not go beyond the cyclone.

Electrostatics has been applied in the development of gas cleaning devices, however most of these devices tend to be too cumbersome. The developed cyclone is based on the conventional design, which is less complicated and cheap to manufacture.

In this paper, a 3D DEM program TRUBAL, which is capable of calculating the contact between particles considering friction and local plastic deformation, is employed to study the evolution of internal structure of particle assemblies during the consolidation process. Uniaxial powder compaction process is simulated in a cubic periodic unit cell by applying the strain rate to the individual particles. The selection of the proper time steps in DEM for quasi‐static case is discussed. Results in particle scale (microscopic) are obtained and correlated to the statistical bulk response of the assembly. The effects of the microscopic properties of particles (such as friction, plastic contact) on the bulk mechanical response are examined by numerical tests. Correlations between the microscopic properties of particles and the macroscopic continuum behaviours of compacts are discussed. These discussions make it possible to fit DEM results at a macroscopic scale to the experimental measurements by adjusting the particle properties in DEM calculation. An example test is carried out to demonstrate that DEM results could be fitted properly to the experimental results, in the mean time, also provide some microscopic results which are hard to be measured. DEM has the potential to incorporate the microscopic properties of particles into a proper continuum model to perform combined macro and micro study of the powder compaction process.

Polymeric particulate composites with thermoplastics, especially polypropylene (PP) matrix with mineral fillers, are of great practical importance due to their simple possibility of modifying mechanical properties and reducing the price/volume ratio of the resulting material. Both filler properties and interface properties have a great effect on the mechanical properties, primarily on stiffness and toughness, of the resulting composite material. Good final dispersion of the filler particles also plays a very important role. To reach the best adhesion and distribution of the particles, various procedures are carried out for activation of the particles. Therefore, the purpose of this paper is to investigate and discuss the effect of using plasma as a tool for treating commercially available CaCO₃ nanoparticles in PP matrix.

The effect of the composite structure on its mechanical properties was studied from an experimental as well as a theoretical point of view. For an experimental study, four PP matrix were chosen. For use as filler, the commercially available precipitated surface-treated calcium carbonate was chosen. The composites were prepared with 5, 10, and 15 wt% of fillers. The sequence of expositions of plasma was chosen to verify the optimal treatment duration. The filler particles were characterized by several structure analytical methods. The composite mechanical properties were characterized by tensile, bending, impact, and creep tests. The deformation behavior of the three-phase composite with homogeneously distributed coated particles was numerically simulated on a microscopic scale.

The main conclusions of this work can be summarized as follows: with the use of plasma to the precipitated calcium carbonate, composites with well-dispersed particles can be prepared; the surface modification using plasma is done mainly by grafting –OH groups onto the particles’ surface; a synergetic effect of modifier enhancing the performance was observed; performance modifier increases the resistance against viscoelastic strain; and the size of the particles and their volume content generally lead to increase in the macro modulus of the composite.

Plasma, as a tool for treating the inorganic fillers, enables to destroy the agglomerates in composite, which is the basic way on how to optimally utilize the synergetic effect of composite with PP matrix.

This paper presents the results of a Discrete Element Method study on the influence of particle shape on the strength and deformation behaviour of two dimensional assemblages of ellipse‐shaped particles. Assemblages of particles with varying individual particle aspect ratio were formed with a preferred bedding plane, isotropically compressed with varying isotropic confining stresses and then sheared with biaxial compression. The results indicate that Discrete Element analysis using two dimensional ellipse‐shaped particles produces mechanical behaviour which is similar both quantitatively and qualitatively to the behaviour of real granular materials. Even small particle out‐of‐roundness increases the observed macroscopic strength significantly. In systems composed of flatter particles, particle rotations are greatly inhibited. Decomposing relative contact displacements into contributions due to particle rotation and translation demonstrates that most of the displacements in round particle systems are due to individual particle rotation.

The purpose of this paper is to model the particle capture of elliptic magnetic matrices for parallel stream type high magnetic separation, which can be a guidance for the development of novel elliptic cylinder matrices for high-gradient magnetic separation (HGMS).

The magnetic field distribution around the elliptic matrices is investigated quantitatively and the magnetic field and gradient were calculated. The motion equations of the magnetic particles around the matrices were derived and the particle capture cross-section of elliptic matrices was studied and was compared with that of the conventional circular matrices.

Elliptic matrices can present larger particle capture cross-section than the conventional circular matrices and can be a kind of promising matrices to be applied to HGMS.

There is little literature investigating the magnetic characteristics and the particle capture of the elliptic matrices in HGMS, the study is of great significance for the development of novel elliptic magnetic matrices in HGMS.

The increasing demand for fine pitch interconnections has led to a growth of interest in anisotropically conductive adhesives (ACAs) as an alternative to solder joints in high density applications. The understanding of the conduction mechanisms for ACAs is of vital importance when choosing the right adhesive for a specific application. In the conductivity model, a formula has been created that can be used to estimate how the degree of deformation of the particles effects the resistance, especially in the case of soft metal‐coated polymer particles. Using this model, it is possible to estimate the total contact resistance. Some comparisons are made with real measurements for gold and indium‐tin‐oxide (ITO) surfaces, using gold‐coated polymer particles and gold bumped chips. For gold surfaces, the measurements have shown reasonably good correlation with the model. In the case of the ITO surface, the interface resistances seem to be the major part of the total resistance.

The purpose of this paper is to use comprehensive model to investigate the effects of particle physical properties on in-flight nano-particles behavior for the radio frequency suspension plasma spray.

In this paper, both the effects thermal properties of solvent and solid particle on the evolution of particle size, velocity and temperature are discussed. Besides, the numerical analysis is also conducted to investigate the influences of particle physical properties on the characteristic distributions of particles for poly-disperse cases.

Results show the thermal properties of solvent have critical effects on the discharged point of the solid particles, but little influence on the final particle velocity and size, as well as their distributions. The final state of particle temperature is mainly determined by the solid particle thermal properties, especially depending on the boiling point.

Most of the former studies took the experimental approaches and mainly focussed on the operating conditions effects. While beyond the operating conditions, the variety of particle physical and thermal properties also has strong effect on particle heating performance.

The purpose of this paper is to study the correlation between the dynamic features of the running-in attractor and the wear particle group, so as to characterize the running-in attractor by means of the wear particle group.

Wear particles are collected in phased wear experiments, and their dynamic features are investigated by the equivalent mean chord length L. Then, the correlation between the equivalent mean chord length L and the correlation dimension D of the running-in attractor is studied.

In the wear process, the equivalent means chord length L first decreases, then remains steady, and finally increases, this process agrees with the increase, stabilization and decrease of the correlation dimension D. Therefore, the wear particle group has a dynamic nature, which characterizes the formation, stabilization, and disappearance of a running-in attractor. Consequently, the dynamic characteristics and evolution of a running-in attractor can be revealed by the wear particle group.

The intrinsic relationship between the wear particle group and the running-in attractor is proved, and this is advantageous for further revealing the dynamic features of the running-in attractor and identifying the wear states.