Precision molding is a replicative production method for the mass production of complex glass optics in high precision. In contrast to the traditional material removal process, such as grinding and polishing, the surface as well as the entire shape of the optical component is created by deforming glass at elevated temperatures using precise molding tools with optical surfaces. The molded glass components present high shape accuracy and surface finish after the molding process, therefore no further processing is required. During the molding process, the glass is heated in the molding tool up to above the transition temperature Tg, then pressed into desired shape and cooled down to approximately 200 °C. The precision glass molding is therefore a complex thermo-mechanical process, in which the glass lens undergoes uneven cooling speed and stress distribution. These lead to several drawbacks on the molded glass optics, such as form deviation, index change and fracture. In this study, FEM simulation was employed in order to achieve preliminary understanding of the molding process. The FEM model included viscoelasticity behavior of glass material (stress-relaxation, structure-relaxation and thermos-rheological simplicity), as well as thermodynamics model of the molding machine. In the form of a case study of a real molding example, the form deviation, index change and fracture of the molded glass optic were predicted in advance of the molding experiment by means of the numerical calculation of thermal shrinkage, volume change and stress distribution respectively. The good agreement between simulation results and molding experiment results proves the accuracy of the developed FEM model.

In this work, we demonstrate that the phase field crystal (PFC) method can be applied to identify and predict the microstructure evolution during the solidification of the BCC metals in additive manufacturing. The results reveal the columnar structure of the grains, which matches the grain growth observed in real samples produced with the additive manufacturing technique. The effect of ambient temperature, seed-seed distance and seed-seed misorientation on the grain growth has been investigated. In addition, the formation of crystal defects during the process is recorded and the resulted long-range stresses are calculated using the eigenstresses theory.

This article reports investigation of the effects of high-rate stochastic micro-mechanics on the produced particulate size distribution during ball milling of reactive bimetallic foils (nanoheaters), by experimental and computational modeling. In particular, Ni-Al foils are ball-milled at various load charges, revolution rates and process durations, and the resulting particulate geometries are characterized by micrograph statistical analysis. Numerical simulation of the evolving particulate structure is based on coalescence and fragmentation of flexible monometallic ellipsoidal primitives, impacted by milling balls and vial walls with kinetic theory-based kinematics. Particulates are constrained by discrete compliant and continuum media and undergo conceptual ideal elastic transformations modeled by strain energy methods, and recast into inelastic frictional and plasticity-driven welding and fracture events. Finally the theoretical model predictions of particulate size distribution are validated against laboratory microscopy observations.

Pulsed electron beam ablation (PEBA) has proven to be a promising and powerful technique for the growth of high quality thin films. Pulsed electron beam film deposition consists of many physical processes including target material heating, target ablation, plasma plume expansion, and film growth on a substrate. Plasma plume expansion into a vacuum or an ambient gas is a fundamental issue in PEBA as the quality of thin films deposited onto the substrate depends on the composition, energy and density of particles ejected from the target. In the present study, gas-dynamics equations are solved to investigate plasma expansion induced by interaction of a nanosecond electron beam pulse (∼100 ns) with a graphite target in an argon atmosphere at reduced pressure. The spatio-temporal profiles of the temperature, pressure, velocity, and density of the plasma plume are numerically simulated for a beam efficiency of 0.6 and accelerating voltage of 15 kV. The preliminary results show a rich variety of behaviors. The model is validated by comparing some of the obtained simulation results with experimental data available in the literature.

We demonstrate that Additive Manufacturing (3D printing) is a viable approach to rapidly prototype personalised fins for surfboards. Surfing is an iconic sport that is extremely popular in coastal regions around the world. We use computer aided design and 3D printing of a wide range of composite materials to print fins for surfboards, e.g. ABS, carbon fibre, fibre glass and amorphous thermoplastic poly(etherimide) resins. The mechanical characteristics of our 3D printed fins were found to be comparable to commercial fins. Computational fluid dynamics was employed to calculate longitudinal (drag) and tangential (turning) forces, which are important for surfboard maneuverability, stability and speed. A commercial tracking system was used to evaluate the performance of 3D printed fins under real-world conditions (i.e. surfing waves). These data showed that the surfing performance of surfboards with 3D printed fins is similar to that of surfboards with commercial fins.

This work aims to develop magnetic fibers whose magnetic properties improve upon fibers produced using existing techniques. The goal of this work is to develop magnetic fibers that are magnetically anisotropic, with high squareness ratios when the fibers are oriented parallel to the applied magnetic field, and lower square ratios when the fibers are oriented perpendicular to the field. In this work, barium hexaferrite particles were embedded in a Sylgard elastomer matrix. The magnetic material was placed on a sheet of acrylic with spacers on opposite ends. A top sheet of acrylic was placed on the spacers. A 0.5 T permanent magnet was placed on top of the upper piece of acrylic. Magnetic fibers were drawn as the material aligned itself with the magnetic field lines of the magnet. After the fibers cured they were tested on a vibrating sample magnetometer at angles parallel and perpendicular to the field. The results showed that the fibers were highly anisotropic, with an average squareness ratio of 0.82 in the easy axis and an average squareness ratio of 0.34 in the hard axis. Although, the fibers were anisotropic, there was a high variability in the magnetization when normalized by the total volume of the fiber. This indicates that the magnetic content varies within each fiber, likely due to the variation in the strength of the magnetic field lines of the external magnet. This research demonstrated that magnetic fibers with high anisotropy can be fabricated, but the amount of magnetic material in each fiber from the same batch needs to be tuned to decrease variability. Fitting this experimentally found squareness ratio to a von Mises distribution, the concentration parameter was calculated to be 0.14. This indicates the magnetic domains within each fiber are highly aligned with the externally applied field.