{"id":{"repo_id":"buffalo","oai_identifier":"oai:ubir.buffalo.edu:10477/78650"},"canonical_url":"https://search.dev.ndltd.org/etd/buffalo/oai:ubir.buffalo.edu:10477/78650","repository":{"repo_id":"buffalo","name":"Buffalo","base_url":"https://ubir.buffalo.edu/oai/request"},"display":{"title":"Computational Modelings of Droplet Deposition and Coalescence for Drop-Wise Additive Manufacturing","abstract":"M.S.","abstract_html":"M.S.","abstract_has_math":false,"creators":["Vishnoi, Priyanshu; 0000-0002-5676-3870"],"institution":"State University of New York at Buffalo","degree_name":null,"degree_level":null,"degree_discipline":null,"degree_department":null,"school":null,"contributors":["Swihart, Mark","Chemical and Biological Engineering"],"advisors":[],"committee_chairs":[],"committee_members":[],"year":2018,"date_issued":"2018-10-26T02:57:31Z","date_published":"2018-10-26T02:57:31Z","updated_at":"2026-07-27T19:05:14Z","subjects":["chemical engineering"],"languages":["eng"],"rights":["Users of works found in University at Buffalo Institutional Repository (UBIR) are responsible for identifying and contacting the copyright owner for permission to reuse. University at Buffalo Libraries do not manage rights for copyright-protected works and cannot assist with permissions.","Copyright retained by author."],"rights_urls":[],"identifier_entries":[]},"links":{"outbound_url":"http://hdl.handle.net/10477/78650","outbound_label":"Handle","outbound_source":"dc:identifier"},"metadata_groups":[{"id":"people","label":"People","entries":[{"key":"dc:contributor","label":"Contributor","values":["Swihart, Mark","Chemical and Biological Engineering"]},{"key":"dc:creator","label":"Author","values":["Vishnoi, Priyanshu; 0000-0002-5676-3870"]}]},{"id":"academic_context","label":"Academic Context","entries":[{"key":"dc:date","label":"Dc Date","values":["2018-10-26T02:57:31Z","2018","2018-08-12 18:43:04"]},{"key":"dc:publisher","label":"Institution","values":["State University of New York at Buffalo"]},{"key":"dc:type","label":"Dc Type","values":["Text","Thesis"]}]},{"id":"subjects_keywords","label":"Subjects and Keywords","entries":[{"key":"dc:subject","label":"Dc Subject","values":["chemical engineering"]}]},{"id":"language_rights","label":"Language and Rights","entries":[{"key":"dc:language","label":"Dc Language","values":["eng"]},{"key":"dc:rights","label":"Dc Rights","values":["Users of works found in University at Buffalo Institutional Repository (UBIR) are responsible for identifying and contacting the copyright owner for permission to reuse. University at Buffalo Libraries do not manage rights for copyright-protected works and cannot assist with permissions.","Copyright retained by author."]}]},{"id":"identifiers","label":"Identifiers","entries":[{"key":"dc:identifier","label":"Identifier","values":["http://hdl.handle.net/10477/78650"]}]},{"id":"additional","label":"Additional Metadata","entries":[{"key":"dc:description","label":"Description","values":["M.S.","Drop-on-demand additive manufacturing is a novel 3D printing technique. Additive manufacturing (AM) is a bottom-up manufacturing process in which material is joined or solidified under computer control to create a three-dimensional object. In this thesis, we analyze an innovative additive manufacturing method that involves the drop-on-demand (DOD) printing of molten aluminum droplets to build three-dimensional (3D) metal structures of arbitrary shape. Aluminum alloy Aluminum 6061 is used as the metal in our study. This technique is based on magnetohydrodymanic (MHD) droplet generation. In conventional three dimensional (3D) metal printing technique such as Selective Laser Melting (SLM), Direct Laser Fabrication (DLF), Electron Beam Solid Fabrication (EBSF) and related methods, an object is created by layer-by-layer patterned deposition of heated material on a moving substrate. In MHD-base DOD additive manufacturing of liquid metal, a metal spooled wire (approximately 1 mm diameter) is fed into a ceramic reservoir where it is resistively heated to form molten metal. The molten metal flows from the reservoir into an ejection chamber via capillary forces. The assembly of ejection chamber and ejection reservoir is also known as the printhead. The printhead is surrounded by a solenoid copper coil that is electrically pulsed to produce a transient magnetic field (B) within it. The magnetic field, in turn induces a circulating current density (J), that back couples to the transient magnetic field thereby generating a MHD Lorentz force density (fMHD) within the molten metal in the ejection chamber, whose radial component creates a transient “effective pressure” (P) pulse that ejects a liquid metal droplet through the orifice. The metal droplet travels through the argon-gas atmosphere and deposits on the object being fabricated. The argon gas shroud is needed to prevent oxidation of liquid aluminum. We present an analysis of a commercial MHD-based printing system under development by Vader Systems (www.vadersystems.com) and introduce a computational model that helps to predict system performance. We discuss the underlying physics and the thermos-fluidic aspects of droplet deposition. We also demonstrate the use of Computational Fluid Dynamics (CFD) to analyze the effects of various parameters on droplet deposition, coalescence and solidification, and ultimately on the final printed structure. A finite-volume thermo-fluidic analysis was performed using the commercially available CFD software Flow-3D (www.flow3d.com). Computational simulations were performed to understand and analyze the droplet-air and droplet-substrate interactions, and to study the effects of various parameters on the final printed structures. The presented models provide insight into the underlying mechanism behind droplet deposition and droplet solidification on the surface. We also demonstrate good agreement between our computational models and measured data."]},{"key":"dc:format","label":"Dc Format","values":["application/pdf"]},{"key":"dc:title","label":"Title","values":["Computational Modelings of Droplet Deposition and Coalescence for Drop-Wise Additive Manufacturing"]}]}],"canonical_facts":{"dc:contributor":["Swihart, Mark","Chemical and Biological Engineering"],"dc:creator":["Vishnoi, Priyanshu; 0000-0002-5676-3870"],"dc:date":["2018-10-26T02:57:31Z","2018","2018-08-12 18:43:04"],"dc:description":["M.S.","Drop-on-demand additive manufacturing is a novel 3D printing technique. Additive manufacturing (AM) is a bottom-up manufacturing process in which material is joined or solidified under computer control to create a three-dimensional object. In this thesis, we analyze an innovative additive manufacturing method that involves the drop-on-demand (DOD) printing of molten aluminum droplets to build three-dimensional (3D) metal structures of arbitrary shape. Aluminum alloy Aluminum 6061 is used as the metal in our study. This technique is based on magnetohydrodymanic (MHD) droplet generation. In conventional three dimensional (3D) metal printing technique such as Selective Laser Melting (SLM), Direct Laser Fabrication (DLF), Electron Beam Solid Fabrication (EBSF) and related methods, an object is created by layer-by-layer patterned deposition of heated material on a moving substrate. In MHD-base DOD additive manufacturing of liquid metal, a metal spooled wire (approximately 1 mm diameter) is fed into a ceramic reservoir where it is resistively heated to form molten metal. The molten metal flows from the reservoir into an ejection chamber via capillary forces. The assembly of ejection chamber and ejection reservoir is also known as the printhead. The printhead is surrounded by a solenoid copper coil that is electrically pulsed to produce a transient magnetic field (B) within it. The magnetic field, in turn induces a circulating current density (J), that back couples to the transient magnetic field thereby generating a MHD Lorentz force density (fMHD) within the molten metal in the ejection chamber, whose radial component creates a transient “effective pressure” (P) pulse that ejects a liquid metal droplet through the orifice. The metal droplet travels through the argon-gas atmosphere and deposits on the object being fabricated. The argon gas shroud is needed to prevent oxidation of liquid aluminum. We present an analysis of a commercial MHD-based printing system under development by Vader Systems (www.vadersystems.com) and introduce a computational model that helps to predict system performance. We discuss the underlying physics and the thermos-fluidic aspects of droplet deposition. We also demonstrate the use of Computational Fluid Dynamics (CFD) to analyze the effects of various parameters on droplet deposition, coalescence and solidification, and ultimately on the final printed structure. A finite-volume thermo-fluidic analysis was performed using the commercially available CFD software Flow-3D (www.flow3d.com). Computational simulations were performed to understand and analyze the droplet-air and droplet-substrate interactions, and to study the effects of various parameters on the final printed structures. The presented models provide insight into the underlying mechanism behind droplet deposition and droplet solidification on the surface. We also demonstrate good agreement between our computational models and measured data."],"dc:format":["application/pdf"],"dc:identifier":["http://hdl.handle.net/10477/78650"],"dc:language":["eng"],"dc:publisher":["State University of New York at Buffalo"],"dc:rights":["Users of works found in University at Buffalo Institutional Repository (UBIR) are responsible for identifying and contacting the copyright owner for permission to reuse. University at Buffalo Libraries do not manage rights for copyright-protected works and cannot assist with permissions.","Copyright retained by author."],"dc:subject":["chemical engineering"],"dc:title":["Computational Modelings of Droplet Deposition and Coalescence for Drop-Wise Additive Manufacturing"],"dc:type":["Text","Thesis"]},"updated_at":"2026-07-27T19:05:14Z"}