Browsing by Author "Sivarupan, Tharmalingam"

Now showing 1 - 3 of 3
  • Thumbnail Image
    ItemOpen Access
    Modeling and simulation of cold hearth continuous casting of titanium alloys
    (Springer, 2025-03-03) Mozhi Varman, J. P. Arul; Sivarupan, Tharmalingam; Georgarakis, Konstantinos; Salonitis, Konstantinos; Jolly, Mark
    In the present study, an alternative sustainable method of manufacturing Ti6Al4V alloys from industrial scraps/swarfs is discussed. CFD modeling and simulation of cold hearth continuous casting process is done using FLOW-3D TruVOF and FAVOR techniques. A high-performance computing is utilised to optimise the computing resources to simulate the hydrodynamic and thermal behaviour of the liquid metal. Simulations with different superheating temperatures is conducted to understand the flow properties and solidification. These findings provide valuable insights into understanding of flow properties and thermal distribution for reliable molten metal delivery contributing to efficient recycling and sustainable manufacturing processes.
  • Thumbnail Image
    ItemOpen Access
    A review on the progress and challenges of binder jet 3D printing of sand moulds for advanced casting
    (Elsevier, 2021-02-10) Sivarupan, Tharmalingam; Balasubramani, Nagasivamuni; Saxena, Prateek; Nagarajan, Devarajan; El Mansori, Mohamed; Salonitis, Konstantinos; Jolly, Mark R.; Dargusch, Matthew S.
    3D sand mould printing through binder jetting can solve many technical issues in casting including part consolidation, design of parts to optimise the consumption of materials and hazardous chemicals, and on-demand and any size part manufacturing near the customer. Incorporating artificial intelligence in optimising the design of moulds, printing process parameters, and solidification processes may help automate a production facility and reduce labour time. Elimination of hazardous chemicals from industrial use may be a challenge. Therefore, an alternative technology to fuse the sand particles during printing or an environmentally friendlier alternative option for the binders and other consumables should be utilised with the 3D sand printing process. Properties of parts produced using 3D printed sand moulds are better than the properties of parts produced using traditional casting due to this technology's benefits mentioned above. Though this technology is a supportive enabling technology for the traditional casting processes rather than a competing technology. This technology is causing a paradigm shift in casting design because of the mould geometries achievable using the sand moulds' additive manufacturing. This paper reviews the first twenty years of research and challenges in developing 3D sand printing as an innovation for sustainable manufacturing.
  • Thumbnail Image
    ItemOpen Access
    Sedimentation of inclusions in melts of aerospace structural aluminium alloy castings: a sustainable approach
    (Springer, 2025-03-03) Sivarupan, Tharmalingam; Jayaraman Palanivel, Arul; Georgarakis, Konstantinos; Forde, John; Rawding, Joseph; Shaw, Ben; Salonitis, Konstantinos; Jolly, Mark R.
    Achieving the full potential of mechanical and other properties in aerospace structural aluminium alloy castings is often hindered by the presence of detrimental inclusions in the melt during casting. The inclusions arise from high-temperature chemical reactions and the dissolution of substances in contact with the melt or pre-existing in the alloy. Suitable additions to the melt can precipitate on the inclusions and cause them to sediment, resulting in cleaner melt. Simulation techniques were employed with commercial software packages (Flow3D) using high-performance cluster computing (HPC) facilities to analyse the behaviour of impurity particles of various sizes and distributions under different boundary conditions such as temperature, pressure, flow rate, and heat transfer. The simulations provide insights into the sedimentation process to identify effective methods for eliminating/reducing these particles from the melt. Some of the practical melt holding or processing challenges, and mitigations, are also discussed.