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Conference Papers by Nick Lavery

Research paper thumbnail of (2014) Computational Methodology for Optimal Design of Additive Layer Manufactured Turbine Bracket

When designing critical components for aircraft, cars, and vehicles or machinery in general, toda... more When designing critical components for aircraft, cars, and vehicles or machinery in general, today’s designers are constantly challenged with the trade off between two main aspects: on the one hand performance requirements for strength and stiffness and on the other hand size and weight. Nowadays, there are software tools to aid designers in optimizing their part designs. However, manufacturing methods restrict designer ability to take advantage of these optimized structures beyond a certain level of complexity. Additive manufacturing is lifting the constraints of traditional manufacturing processes, giving designers the ability to grow practically any shape, enabling the use of fully optimized lightweight designs that do not sacrifice performance. The adequate use of tools for optimization, finite element analysis (FEA) and computer aided design (CAD) permit to reach very good results in short times. In this paper a procedure and results of one case of study are presented. The softwar...

Papers by Nick Lavery

Research paper thumbnail of Rapid Printing of 3D Printed SnSe Thermoelectric Generators Utilising an Inorganic Binder

Zenodo (CERN European Organization for Nuclear Research), Jan 26, 2023

Research paper thumbnail of Studying Microstructure and Crystallinity of Polypropylene in an Injection Moulded Medical Bin Lid

InImpact: The Journal of Innovation Impact, 2014

Properties of injection moulded parts such as crystallinity and size of spherulite are strongly i... more Properties of injection moulded parts such as crystallinity and size of spherulite are strongly influenced by processing parameters. A polypropylene (PP) sharps bin lid manufactured via injection moulding shows a variable distribution of temperature along the surface on ejecting at the end of the moulding cycle. This discrepancy subsequently necessitates the characterization of crystallinity and spherulite size for the bin lid at its face and corners. DSC, polarized optical microscopy and scanning electron microscopy were used for this analysis. Results of DSC analysis reveal that crystallinity does not change throughout the bin lid and its average value for corner and face is approximately 30 %. Use of the etchant to reveal spherulites in PP and low voltage SEM analysis has proven to be an efficient method for microstructural analysis in polymers and does not require gold coat to be applied on the polymer. POM images of slow cooled PP thin films (2 oC/mins approximately) reveal com...

Research paper thumbnail of A Methodology for Automated Pellet size Distribution in a Pellet Mill

In this work the feasibility of pellet size distribution using images captured from the operator’... more In this work the feasibility of pellet size distribution using images captured from the operator’s sight glass of the moving pellet bed using a standard digital camera is investigated. The pellet size distribution is determined using a bespoke circle detection program which is able to fit circles to pellet edges, neural networks are used to match predicted distributions to actual distributions and discrete element modelling is used to create a large quantity of rendered images with known distributions for network training. The results show that the circle detection algorithm is able to find a high percentage of pellets in an image and find their sizes. Neural networks are then able to use the predicted pellet size distributions to give a good prediction of the actual distributions and are able to account for segregation effects in the pellet beds. This demonstrates that an online pellet sizing scheme is feasible in nickel pellet production.

Research paper thumbnail of A review of Computational Modelling of Additive Layer Manufacturing - multi-scale and multi-physics

InImpact: The Journal of Innovation Impact, 2014

This paper presents a review of the state-of-the-art in computational modelling of the Additive L... more This paper presents a review of the state-of-the-art in computational modelling of the Additive Layer Manufacturing (ALM) process, with a description and examples of models being developed at Swansea University, and a comparison to efforts from other commercial and academic organisations. As a process, ALM is strongly based on computational control and the production of net- shape parts, computational modelling is being used to understand and improve the process, as well as to create new and optimised functionality of components. Modelling efforts range from discrete element models of powder flow, to micro-and macro- scale models of the laser melt-pool, coupled thermal-structural models to predict residual stress, and automated optimisation methods for the development of new components. Modelling can also be used at a microstructural level for the prediction of the bulk properties. In all instances, the modelling is used with the purpose of increasing understanding to address known ...

Research paper thumbnail of Prediction of phase, hardness and density of high entropy alloys based on their electronic structure and average radius

Journal of Alloys and Compounds, 2021

Research paper thumbnail of The Effect of Scandium Ternary Intergrain Precipitates in Al-Containing High-Entropy Alloys

Research paper thumbnail of Formation and Disruption of W-Phase in High-Entropy Alloys

Research paper thumbnail of Combinatorial development and high throughput materials characterisation of steels

Ironmaking & Steelmaking, 2015

Research paper thumbnail of Computational Methodology for Optimal Design of Additive Layer Manufactured Turbine Bracket

When designing critical components for aircraft, cars, and vehicles or machinery in general, toda... more When designing critical components for aircraft, cars, and vehicles or machinery in general, today’s designers are constantly challenged with the trade off between two main aspects: on the one hand performance requirements for strength and stiffness and on the other hand size and weight. Nowadays, there are software tools to aid designers in optimizing their part designs. However, manufacturing methods restrict designer ability to take advantage of these optimized structures beyond a certain level of complexity. Additive manufacturing is lifting the constraints of traditional manufacturing processes, giving designers the ability to grow practically any shape, enabling the use of fully optimized lightweight designs that do not sacrifice performance. The adequate use of tools for optimization, finite element analysis (FEA) and computer aided design (CAD) permit to reach very good results in short times. In this paper a procedure and results of one case of study are presented. The softwar...

Research paper thumbnail of Computational modeling of creep-based fatigue as a means of selecting lead-free solder alloys

Microelectronics Reliability, 2014

The primary aim of this investigation was to understand the effect of temperature fluctuations on... more The primary aim of this investigation was to understand the effect of temperature fluctuations on a number of various solder materials namely SAC105, SAC305, SAC405 and Sn-36Pb-2Ag. To achieve this objective, three different classic joint assemblies (a ball joint, a test specimen joint and finger lead joint) were modeled which provided the foundation for the creep and fatigue behaviors simulation. Anand's viscoplasticity as a constitutive equation was employed to characterize the behavior of solders numerically under the influence of thermal power cycles (80-150°C) and thermal shock cycles (À40 to 125°C). To extend the research outcome for industrial use, two additional research activities were carried out. One of them was to obtain lifetime-predictions of solder joints based on Coffin Manson concept. The other one focused on parameterization to obtain the ideal solder thickness under the consideration of plastic strain and economic benefit.

Research paper thumbnail of Life cycle assessment of gas atomised sponge nickel for use in alkaline hydrogen fuel cell applications

Journal of Power Sources, 2013

Life cycle assessment of gas atomized sponge nickel for use in alkaline hydrogen fuel cell applic... more Life cycle assessment of gas atomized sponge nickel for use in alkaline hydrogen fuel cell applications,

Research paper thumbnail of Life cycle assessment of sponge nickel produced by gas atomisation for use in industrial hydrogenation catalysis applications

The International Journal of Life Cycle Assessment, 2012

Research paper thumbnail of CFD Modelling of the Effect of Fillets on Fin Drag

Research paper thumbnail of Effects of hot isostatic pressing on the elastic modulus and tensile properties of 316L parts made by powder bed laser fusion

Materials Science and Engineering: A, 2017

Research paper thumbnail of 3D solid fin model construction from 2D shapes using non-uniform rational B-spline surfaces

Advances in Engineering Software - AES, 2006

A computer aided design (CAD) tool has been specifically developed for rapid and easy design of s... more A computer aided design (CAD) tool has been specifically developed for rapid and easy design of solid models for surfboard and sailboard fins. This tool simplifies the lofting of advanced fin cross-sectional foils, in this instance based upon the family of standard airfoil series set by the National Advisory Committee for Aeronautics (NACA), whilst retaining a basic parametric description at each cross-section.This paper describes the way in which non-uniform rational B-spline (NURBS) surfaces are created from 2D profile splines, and are then used to generate 3D geometrical surfaces of the fins, which can be imported directly into commercial software packages for finite element stress analysis (FEA) and computational fluid dynamics (CFD).Pressure distributions, lift and drag forces are determined from a CFD flow analysis for various fins designed with this tool, and the results suggest that the incorporation of advanced foils into surfboard fins could indeed lead to increased perfor...

Research paper thumbnail of Heat Transfer Analysis of the Curing Process on an Organic Paint Strip Line

Research paper thumbnail of Case studying technology transfer in an Objective 1 area

Two major initiatives are in place in Wales aiming to create a strong and internationally competi... more Two major initiatives are in place in Wales aiming to create a strong and internationally competitive SME (Small and Medium Size Enterprise) sector. One is the Technology Exploitation Programme (TEP) and the other is the Centres of Excellence for Technology and Industrial Collaboration (CETIC) programme.

Research paper thumbnail of 3D solid fin model construction from 2D shapes using non-uniform rational B-spline surfaces

Advances in Engineering Software, 2006

A computer aided design (CAD) tool has been specifically developed for rapid and easy design of s... more A computer aided design (CAD) tool has been specifically developed for rapid and easy design of solid models for surfboard and sailboard fins. This tool simplifies the lofting of advanced fin cross-sectional foils, in this instance based upon the family of standard airfoil series set by the National Advisory Committee for Aeronautics (NACA), whilst retaining a basic parametric description at each cross-section.

Research paper thumbnail of Presentation SDM 2014 Hector Ulises Levatti

Research paper thumbnail of (2014) Computational Methodology for Optimal Design of Additive Layer Manufactured Turbine Bracket

When designing critical components for aircraft, cars, and vehicles or machinery in general, toda... more When designing critical components for aircraft, cars, and vehicles or machinery in general, today’s designers are constantly challenged with the trade off between two main aspects: on the one hand performance requirements for strength and stiffness and on the other hand size and weight. Nowadays, there are software tools to aid designers in optimizing their part designs. However, manufacturing methods restrict designer ability to take advantage of these optimized structures beyond a certain level of complexity. Additive manufacturing is lifting the constraints of traditional manufacturing processes, giving designers the ability to grow practically any shape, enabling the use of fully optimized lightweight designs that do not sacrifice performance. The adequate use of tools for optimization, finite element analysis (FEA) and computer aided design (CAD) permit to reach very good results in short times. In this paper a procedure and results of one case of study are presented. The softwar...

Research paper thumbnail of Rapid Printing of 3D Printed SnSe Thermoelectric Generators Utilising an Inorganic Binder

Zenodo (CERN European Organization for Nuclear Research), Jan 26, 2023

Research paper thumbnail of Studying Microstructure and Crystallinity of Polypropylene in an Injection Moulded Medical Bin Lid

InImpact: The Journal of Innovation Impact, 2014

Properties of injection moulded parts such as crystallinity and size of spherulite are strongly i... more Properties of injection moulded parts such as crystallinity and size of spherulite are strongly influenced by processing parameters. A polypropylene (PP) sharps bin lid manufactured via injection moulding shows a variable distribution of temperature along the surface on ejecting at the end of the moulding cycle. This discrepancy subsequently necessitates the characterization of crystallinity and spherulite size for the bin lid at its face and corners. DSC, polarized optical microscopy and scanning electron microscopy were used for this analysis. Results of DSC analysis reveal that crystallinity does not change throughout the bin lid and its average value for corner and face is approximately 30 %. Use of the etchant to reveal spherulites in PP and low voltage SEM analysis has proven to be an efficient method for microstructural analysis in polymers and does not require gold coat to be applied on the polymer. POM images of slow cooled PP thin films (2 oC/mins approximately) reveal com...

Research paper thumbnail of A Methodology for Automated Pellet size Distribution in a Pellet Mill

In this work the feasibility of pellet size distribution using images captured from the operator’... more In this work the feasibility of pellet size distribution using images captured from the operator’s sight glass of the moving pellet bed using a standard digital camera is investigated. The pellet size distribution is determined using a bespoke circle detection program which is able to fit circles to pellet edges, neural networks are used to match predicted distributions to actual distributions and discrete element modelling is used to create a large quantity of rendered images with known distributions for network training. The results show that the circle detection algorithm is able to find a high percentage of pellets in an image and find their sizes. Neural networks are then able to use the predicted pellet size distributions to give a good prediction of the actual distributions and are able to account for segregation effects in the pellet beds. This demonstrates that an online pellet sizing scheme is feasible in nickel pellet production.

Research paper thumbnail of A review of Computational Modelling of Additive Layer Manufacturing - multi-scale and multi-physics

InImpact: The Journal of Innovation Impact, 2014

This paper presents a review of the state-of-the-art in computational modelling of the Additive L... more This paper presents a review of the state-of-the-art in computational modelling of the Additive Layer Manufacturing (ALM) process, with a description and examples of models being developed at Swansea University, and a comparison to efforts from other commercial and academic organisations. As a process, ALM is strongly based on computational control and the production of net- shape parts, computational modelling is being used to understand and improve the process, as well as to create new and optimised functionality of components. Modelling efforts range from discrete element models of powder flow, to micro-and macro- scale models of the laser melt-pool, coupled thermal-structural models to predict residual stress, and automated optimisation methods for the development of new components. Modelling can also be used at a microstructural level for the prediction of the bulk properties. In all instances, the modelling is used with the purpose of increasing understanding to address known ...

Research paper thumbnail of Prediction of phase, hardness and density of high entropy alloys based on their electronic structure and average radius

Journal of Alloys and Compounds, 2021

Research paper thumbnail of The Effect of Scandium Ternary Intergrain Precipitates in Al-Containing High-Entropy Alloys

Research paper thumbnail of Formation and Disruption of W-Phase in High-Entropy Alloys

Research paper thumbnail of Combinatorial development and high throughput materials characterisation of steels

Ironmaking & Steelmaking, 2015

Research paper thumbnail of Computational Methodology for Optimal Design of Additive Layer Manufactured Turbine Bracket

When designing critical components for aircraft, cars, and vehicles or machinery in general, toda... more When designing critical components for aircraft, cars, and vehicles or machinery in general, today’s designers are constantly challenged with the trade off between two main aspects: on the one hand performance requirements for strength and stiffness and on the other hand size and weight. Nowadays, there are software tools to aid designers in optimizing their part designs. However, manufacturing methods restrict designer ability to take advantage of these optimized structures beyond a certain level of complexity. Additive manufacturing is lifting the constraints of traditional manufacturing processes, giving designers the ability to grow practically any shape, enabling the use of fully optimized lightweight designs that do not sacrifice performance. The adequate use of tools for optimization, finite element analysis (FEA) and computer aided design (CAD) permit to reach very good results in short times. In this paper a procedure and results of one case of study are presented. The softwar...

Research paper thumbnail of Computational modeling of creep-based fatigue as a means of selecting lead-free solder alloys

Microelectronics Reliability, 2014

The primary aim of this investigation was to understand the effect of temperature fluctuations on... more The primary aim of this investigation was to understand the effect of temperature fluctuations on a number of various solder materials namely SAC105, SAC305, SAC405 and Sn-36Pb-2Ag. To achieve this objective, three different classic joint assemblies (a ball joint, a test specimen joint and finger lead joint) were modeled which provided the foundation for the creep and fatigue behaviors simulation. Anand's viscoplasticity as a constitutive equation was employed to characterize the behavior of solders numerically under the influence of thermal power cycles (80-150°C) and thermal shock cycles (À40 to 125°C). To extend the research outcome for industrial use, two additional research activities were carried out. One of them was to obtain lifetime-predictions of solder joints based on Coffin Manson concept. The other one focused on parameterization to obtain the ideal solder thickness under the consideration of plastic strain and economic benefit.

Research paper thumbnail of Life cycle assessment of gas atomised sponge nickel for use in alkaline hydrogen fuel cell applications

Journal of Power Sources, 2013

Life cycle assessment of gas atomized sponge nickel for use in alkaline hydrogen fuel cell applic... more Life cycle assessment of gas atomized sponge nickel for use in alkaline hydrogen fuel cell applications,

Research paper thumbnail of Life cycle assessment of sponge nickel produced by gas atomisation for use in industrial hydrogenation catalysis applications

The International Journal of Life Cycle Assessment, 2012

Research paper thumbnail of CFD Modelling of the Effect of Fillets on Fin Drag

Research paper thumbnail of Effects of hot isostatic pressing on the elastic modulus and tensile properties of 316L parts made by powder bed laser fusion

Materials Science and Engineering: A, 2017

Research paper thumbnail of 3D solid fin model construction from 2D shapes using non-uniform rational B-spline surfaces

Advances in Engineering Software - AES, 2006

A computer aided design (CAD) tool has been specifically developed for rapid and easy design of s... more A computer aided design (CAD) tool has been specifically developed for rapid and easy design of solid models for surfboard and sailboard fins. This tool simplifies the lofting of advanced fin cross-sectional foils, in this instance based upon the family of standard airfoil series set by the National Advisory Committee for Aeronautics (NACA), whilst retaining a basic parametric description at each cross-section.This paper describes the way in which non-uniform rational B-spline (NURBS) surfaces are created from 2D profile splines, and are then used to generate 3D geometrical surfaces of the fins, which can be imported directly into commercial software packages for finite element stress analysis (FEA) and computational fluid dynamics (CFD).Pressure distributions, lift and drag forces are determined from a CFD flow analysis for various fins designed with this tool, and the results suggest that the incorporation of advanced foils into surfboard fins could indeed lead to increased perfor...

Research paper thumbnail of Heat Transfer Analysis of the Curing Process on an Organic Paint Strip Line

Research paper thumbnail of Case studying technology transfer in an Objective 1 area

Two major initiatives are in place in Wales aiming to create a strong and internationally competi... more Two major initiatives are in place in Wales aiming to create a strong and internationally competitive SME (Small and Medium Size Enterprise) sector. One is the Technology Exploitation Programme (TEP) and the other is the Centres of Excellence for Technology and Industrial Collaboration (CETIC) programme.

Research paper thumbnail of 3D solid fin model construction from 2D shapes using non-uniform rational B-spline surfaces

Advances in Engineering Software, 2006

A computer aided design (CAD) tool has been specifically developed for rapid and easy design of s... more A computer aided design (CAD) tool has been specifically developed for rapid and easy design of solid models for surfboard and sailboard fins. This tool simplifies the lofting of advanced fin cross-sectional foils, in this instance based upon the family of standard airfoil series set by the National Advisory Committee for Aeronautics (NACA), whilst retaining a basic parametric description at each cross-section.

Research paper thumbnail of Presentation SDM 2014 Hector Ulises Levatti

Research paper thumbnail of Prediction of long term stress rupture data for 2124

The standard power law approaches widely used to describe creep and creep fracture behavior have ... more The standard power law approaches widely used to describe creep and creep fracture behavior have not led to theories capable of predicting long-term data. Similarly, traditional parametric methods for property rationalization also have limited predictive capabilities. In contrast, quantifying the shapes of short-term creep curves using the θ methodology introduces several physically-meaningful procedures for creep data rationalization and prediction, which allow straightforward estimation of the 100,000 hour stress rupture values for the aluminum alloy, 2124.