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Hybrid manufacturing processes redefine production dynamics by harnessing the synergistic interplay between process mechanisms, energy sources, and tools to impact manufacturing quality, productivity, and sustainability significantly. Accordingly, this article focuses on hybrid additive manufacturing incremental forming, where additive manufacturing and incremental forming are integrated in a unified setup, driven by a single power source. This integration opens avenues for innovative component and production design, capitalizing on the strengths of both methods while mitigating drawbacks. The fabrication of the hybrid additive manufacturing incremental forming setup involves crucial components like a hybrid extrusion forming unit, supporting plates, hopper-barrel assembly, band heaters, solenoid setup, and a comprehensive control architecture. Addressing challenges, particularly overheating in the hopper, and feeding zone, ensures effective material transformation with the hybrid extrusion forming unit. The subsequent section provides analytical analysis and validation of the hybrid extrusion unit. This technology enhances the entire process and addresses issues related to metal additive manufacturing, such as porosity and material shrinkage. The maximum tensile force sustained in hybrid additive manufacturing incremental forming before fracture demonstrates a notable enhancement of about 20% from 670 N in additive manufacturing to 805 N in hybrid additive manufacturing incremental forming. It also removes micro-cracks, and voids, and improves the inter-layer bonding, as observed through scanning electron microscopy. The results highlight hybrid additive manufacturing incremental forming's superior enhancement of mechanical properties and surface quality compared to traditional additive manufacturing approaches.
Hybrid manufacturing processes redefine production dynamics by harnessing the synergistic interplay between process mechanisms, energy sources, and tools to impact manufacturing quality, productivity, and sustainability significantly. Accordingly, this article focuses on hybrid additive manufacturing incremental forming, where additive manufacturing and incremental forming are integrated in a unified setup, driven by a single power source. This integration opens avenues for innovative component and production design, capitalizing on the strengths of both methods while mitigating drawbacks. The fabrication of the hybrid additive manufacturing incremental forming setup involves crucial components like a hybrid extrusion forming unit, supporting plates, hopper-barrel assembly, band heaters, solenoid setup, and a comprehensive control architecture. Addressing challenges, particularly overheating in the hopper, and feeding zone, ensures effective material transformation with the hybrid extrusion forming unit. The subsequent section provides analytical analysis and validation of the hybrid extrusion unit. This technology enhances the entire process and addresses issues related to metal additive manufacturing, such as porosity and material shrinkage. The maximum tensile force sustained in hybrid additive manufacturing incremental forming before fracture demonstrates a notable enhancement of about 20% from 670 N in additive manufacturing to 805 N in hybrid additive manufacturing incremental forming. It also removes micro-cracks, and voids, and improves the inter-layer bonding, as observed through scanning electron microscopy. The results highlight hybrid additive manufacturing incremental forming's superior enhancement of mechanical properties and surface quality compared to traditional additive manufacturing approaches.
<div>Sodium is used as a coolant in the fast reactor’s primary and secondary loops to transfer enthalpy from the reactor and transport it to the expander. However, handling sodium is difficult, and it can be hazardous if it comes into contact with air, which causes an exothermic reaction. During maintenance of sodium loop components, isolation is typically accomplished with valves. The valve leaking is caused by the seal or the gland. Seal leakage is compensated because it occurs within the line, but gland leakage should be zero because the liquid is harmful. To address this requirement, the author attempted to design a special type of valve in which sodium is allowed to rise through an annular path along the stem and heat transfer is augmented in such a way that the required enthalpy is evacuated to freeze sodium inside the annular path, confirming the fail-safe zero gland leakage. A finned tube assembly is fitted around the stem to achieve this concept of expanded surface heat transfer. However, the issue is to design the fin tube assembly, as well as the number of fins and their dimensions. Normally, these things are done through a series of physical model studies, which is inefficient. In our study, we used conjugate heat transfer analysis to design the fin tube assembly, which was then tested using a physical model.</div>
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