Heat Input Conditions Research Articles

Oscillating Heat Pipe Start-up and Flow Characteristics with Water as Working Fluid

Thermal management has grown more and more problematic as electronic components continue to get faster and smaller. One of the passive two-phase cooling systems are Oscillating heat pipe (OHP) that have the capacity to transmit a significant quantity of thermal energy across long distances. Oscillating heat pipe is a device that has the potential to satisfy this developing requirement. An investigation into the effects of orientation, filling ratio, and heat load on the initiation and characteristics of oscillatory motion, combining numerical simulations with experimental validation. A copper tube with a 2 mm inner diameter and a 2 mm wall thickness is used to fabricate the OHP. The condenser, evaporator, and adiabatic sections are designed with lengths of 50 mm, 50 mm, and 150 mm, respectively. Results showed that the onset of oscillation occurs more rapidly with increasing input heat flux values compared to lower heat input conditions. The amplitude variations of the temperature of evaporator raised with the raising of heating power. The curves for the higher heat inputs (60 and 80 watts) appear to have higher average evaporator temperatures throughout the test compared to the 40-watt curve. Oscillation movement in tubes is proportional to charge ratio, and it is observed that it rises as charge ratio increases. It demonstrates that in Closed-loop oscillating heat pipe, a sufficient charge ratio is required to maintain the motion of oscillation.

Effect of heat input on the microstructure and hydrogen embrittlement susceptibility of the coarse-grain heat-affected zone of CrMo steels generated using a Gleeble 3500 welding simulator

The changes in microstructure and hydrogen embrittlement (HE) susceptibility of the simulated coarse-grain heat-affected zone (CGHAZ) of CrMo steels under three distinct heat input conditions were investigated. The cooling time from 800 °C to 500 °C, represented by t8/5, increased from 100 s to 200 and 400 s.. The sample with t8/5 = 100 s has a microstructure consisting of martensite and a small amount of lower bainite. When the t8/5 was increased to 200 s and 400 s, the HAZ consisted of 65.43 % martensite and 34.57 % lower bainite and 4.53 % martensite with 95.47 % bainite, respectively. The HE susceptibility was assessed by slow strain rate tensile (SSRT) testing of hydrogen-charged samples, and the HE susceptibility index (IHE) declined from 87.89 % to 61.37 % when t8/5 increased from 100 to 400 s. The high dislocation density and hydrogen concentration in the sample with t8/5 = 100 s led to intergranular fracture and incresaed HE susceptibility. The martensite lath and cementite/ferrite interface are the sites of crack initiation in the sample with t8/5 = 200 s. In the sample with a cooling time of 400 s, the martensite/ferrite interfaces are the main crack initiation sites under hydrogen charging.

Evolution of inclusions in DH36 grade ship plate steel during high heat input welding

In this paper, the solid solution and precipitation behavior of inclusions on the surface and 1/2 thickness of the tested steel plate under the condition of welding heat input of 400 kJ/cm is investigated by using laser confocal experiments with hot-rolled state DH36 ship plate steel as the research object, and the mechanism of the effect of inclusions on the phase transformation of an acicular ferrite is revealed. The results show that the inclusions of the tested steel are mainly composed of Oxide-MnS, MnS, Oxide, TiN, Spinel, etc. The amount of inclusions on the surface of the tested steel plate is significantly higher than that at the 1/2 thickness position. During the heating stage, the small inclusions on the surface immediately disappeared, and the large inclusions gradually solidified in the matrix; atomic diffusion occurred at the bond between the inclusions and the matrix; while the small inclusions at the 1/2 thickness position gradually disappeared at the beginning of the heating stage, and the inclusions began to precipitate and grow when the temperature was increased to 990 °C. The acicular ferrite preferentially nucleates and grows near the boundary of the inclusions during the post-weld cooling stage, and its growth ends when two acicular ferrites cross.

Effect of Laser Heat Input on the Microstructures and Low-Cycle Fatigue Properties of Ti60 Laser Welded Joints

In this paper, the effects of laser heat input on the microstructures, tensile strength, and fatigue properties of Ti60 laser welded joints were investigated. The results show that with the increase in laser heat input, the macro morphology of the weld zone (WZ) changes from the Y-type to X-type. In the Y-type WZ, the porosity defects are almost eliminated. In contrast, there are a lot of porosity defects in the lower part of the X-type WZ. The microstructure of the base metal (BM) comprises equiaxed α phases, and β phases are mainly distributed at the boundaries of α phases. The heat-affected zone (HAZ) is comprised of α phases and acicular α′ phases, while the WZ mainly contains acicular α′ phases. With the increase in laser heat input, the quantity of the α phase gradually decreases and the acicular α′ phase gradually increases in the HAZ, and the size of the acicular α′ phase in the WZ gradually decreases. Due to the different microstructures, the hardness of BM is lower than the HAZ and WZ under different laser heat input conditions. In the tensile tests and low-cycle fatigue tests, the welded joints are fractured in BM. The porosity defects do not have decisive effects on the tensile and low-cycle fatigue properties of Ti60 laser welded joints.

Optimizing Elemental Transfer Predictions in Submerged Arc Welding via CALPHAD Technology under Varying Heat Inputs: A Case Study into SiO2-Bearing Flux

With the advancement of the manufacturing industry, performing submerged arc welding subject to varying welding heat inputs has become essential. However, traditional thermodynamic models are insufficient for predicting the effect of welding heat input on elemental transfer behavior. This study aims to develop a model via CALPHAD technology to predict the influence of heat input on essential elements such as O, Si, and Mn when typical SiO2-bearing fluxes are employed. The predicted data demonstrate that the proposed model effectively forecasts changes in elemental transfer behavior induced by varying welding heat inputs. Furthermore, the study discusses the thermodynamic factors affecting elemental transfer behavior under different heat inputs, supported by both measured compositions and thermodynamic data. These insights may provide theoretical and technical support for flux design, welding material matching, and composition prediction under various heat input conditions subject to submerged arc welding processes when SiO2-bearing fluxes are employed.

Microstructures and mechanical behaviour of bimetallic structures of tungsten alloy (90WNiFe) and nickel alloy (In625) fabricated by wire-arc directed energy deposition

ABSTRACT This study reported the fabrication of bimetallic structures (BS) from tungsten alloy (90WNiFe) and nickel alloy (In625) via wire-arc directed energy deposition (DED)-based additive manufacturing (AM). Its microstructures and mechanical properties were investigated for three different heat input conditions: low (180A), medium (200A), and high (220A). The highest average ultimate tensile strength of 618 MPa was achieved in the low heat input condition, with an average elongation of 49%. Although the ultimate tensile strength of the produced BS is lower than that of 90WNiFe and In625 individually, its yield strength closely resembles that of In625 processed by wire-arc DED. Tensile samples from each heat input condition experienced different fracture locations and exhibited distinct fracture morphologies. It can be concluded that the bonding strength is attributed to the diffusion of chromium, nickel, molybdenum, and niobium from In625 into the γ-(Ni, Fe, W) binding matrix of the 90WNiFe substrate.

Joint Characteristics of Cu-Ni Alloy Fabricated by GTAW and MPAW Processes: A Comparative Study

The current work presents a comparative analysis of the joint behavior of Cu-Ni alloy weldments fabricated by Micro-Plasma Arc Welding (MPAW) and Gas Tungsten Arc Welding (GTAW) processes. The Cu-Ni alloy thin sheets are fabricated at different values of heat input (~40-135 J/mm) by MPAW and GTAW processes, respectively. Further, to evaluate their characteristics, joints are subjected to metallurgical, mechanical, and electrochemical testing. The joints fabricated with a higher magnitude of heat input resulted in deteriorated surface quality with a value of Ra~ 6.13 μm. The increased surface roughness value of the joints resulted in a higher corrosion rate (1.273 mm/year). A finer microstructural morphology is achieved for lower heat input condition. Accordingly, the weldment exhibited higher joint efficiency of ~91%.The prominent reason for achieving higher joint strength is related to the presence of lower secondary dendritic arm spacing (SDAS), which enhances the joint strength and ductility for the joints as compared to higher SDAS value. Further, the micro-fractography analysis reveals the presence of micro/macro-voids for high heat input, whereas the existence of numerous dimples of varying size and depth is observed for low heat input condition, implying the role of heat input of utmost importance.

Enhanced mechanical properties and corrosion resistance of friction-stir processed ultralight LA141 magnesium-lithium-aluminum alloy

This study focuses on conducting friction-stir processing (FSP) on 3 mm thick LA141 alloy using different tools. Under low heat input conditions of 600 rpm and 200 mm/min, the use of the WC-Co cemented carbide tool successfully produced a defect-free stir zone. This stir zone exhibited an ultrafine grain structure resulting from continuous dynamic recrystallization. Additionally, the stir zone introduced massive grain boundaries, nanoscale MgAlLi2 particles, and stacking faults. The stir zone displayed a favorable balance of strength and ductility. The enhanced strength is attributed to the inhibitory effect of nanoscale MgAlLi2 particles, grain boundaries, and Lomer-Cottrell locks on dislocation movement. The improved work hardening ability and ductility can be attributed to the increase in stacking faults, Lomer-Cottrell locks, and deformation twins during deformation. Furthermore, the stir zone showed improved corrosion resistance, characterized by lower corrosion current density and larger polarization resistance. This improvement in corrosion resistance can be attributed to multiple factors. These include the reduced defect density, refined and evenly distributed MgLiAl2 particles that weakened galvanic corrosion effects, and the presence of more stable Li2CO3 and Al2O3 compounds that resulted in a compact and protective film.

Influence on the roof stability of EMU induced by welding deformation

The EMU roof with a thin plate structure is prone to buckling deformation during welding, which will affect its stability. Due to the complex structure, large size, and many types of welded joints, it is an urgent problem to solve the influence of different joint shapes on welding deformation and buckling stability in one model. Based on the inherent strain-temperature loading method, the inherent strain data of four kinds of local joint butt, lap, fillet, and plug welding were accurately obtained through joint welding deformation verification. Then the welding deformation simulation and buckling stability analysis were conducted. The results indicate that plug welding will have minimal impact on roof deformation. The roof buckling deformation cannot occur under the original and 1.2 times heat input conditions are selected within the range of the actual given heat source parameters. Under the 1.5 times heat input condition, the roof buckling deformation occurs. The results provide technical support for the selection of the welding process and the roof stability study of the EMU.

Effect of reducing heat input on autogenous TIG welding of Ti–6Al–4V alloy

3 mm-thick Ti–6Al–4V alloy plates were welded in butt joint configuration through autogenous TIG welding method using a trailing gas shielding arrangement. After attaining full penetrated weld joint with appropriate heat input, subsequent experiments were conducted by reducing the heat input, which was obtained through combination of higher welding current and scan speed. An in-depth microstructural analysis of the weld joint executed under different heat input conditions shows a strong correlation with the microhardness, tensile strength, and flexural strength of the weld joint. A significant improvement in the mechanical properties of the weld joint was perceived for employing lower heat input. Alteration in the primary-α, primary-β, and martensite-α phases, due to the variation in heat input, amended the mechanical properties of the weld joint under lower heat input condition. With the reduction of heat input from 0.406 to 0.232 kJ/mm, the tensile and flexural strengths of the weld joint increased from 1020 to 1070 MPa, and from 1015 to 1950 MPa, respectively. The tensile strength of the joint reached up to 98% of the base material at minimum heat input (0.232 kJ/mm). The experimental results show the potential of TIG welding for joining Ti–6Al–4V alloy under low heat input condition.

Laser resolidification of Al-5Mg-0.1Sc alloy: Growth of cells and banded structures

The versatility of Al-Mg alloys makes them well-suited for applications ranging from everyday items to cutting-edge fields like automotive, microelectronics, and aerospace. Moreover, although Al-Mg alloys hold promise for improved surface features in components, research on their laser surface remelting (LSR) remains scarce, presenting an open opportunity to create novel components with these materials. Understanding the growth modes and morphologies of laser surface remelted products is critical in this context. Using a laser instrument, optical microscopy, SEM, XRD, Vickers hardness and image analysis techniques, a correlative analysis of microstructure features and laser heat input is proposed in this research. Furthermore, the Al-5Mg-0.1Sc (wt%) alloy was remelted using two distinct original substrates, each exhibiting varying degrees of microstructure coarsening. Additionally, four distinct laser heat input conditions were applied to each case. All molten pools regions were formed either by cells or bands, with higher growth rates producing a higher fraction of bands. While the variation in the original microstructure of the substrate did not significantly impact both cellular spacings and band/cellular fractions, the microhardness varied remarkably with the reduction in energy input from 10.0 J/mm to 1.7 J/mm. Kurz and Fisher model provided an accurate prediction of the cell spacings formed at the laser molten pool.

Hot Cracking Characteristics During Single-Mode Fiber and Green Laser Welding Processes in Lithium-Ion Battery Pack Manufacturing

Solidification cracking during lithium-ion battery packaging was metallurgically investigated, specifically for Cu-steel dissimilar materials. To this end, single-mode fiber and green lasers were employed under heat input conditions ranging from 1.3 to 8.0 J/mm. For both laser welds, solidification cracking was concentrated in the steel region of the fusion zone, particularly in the locally Cu-depleted region, regardless of the welding condition. Modified self-restraint tests were performed for overlapping dissimilar material combinations to elucidate the mechanism of solidification cracking. Analysis of the solidification cracking surface revealed that approximately 15?30 mass% Cu existed on the surface. Cu was highly enriched with a droplet shape, formed during solidification within the miscibility gap. By calculating the non-equilibrium weld mushy zone range based on the diffusion-controlled Scheil’s model, the solidification cracking in the Cu-depleted region was estimated at 453 K. It was strongly affected by the severe segregation of Cu (95.7 mass%) in the residual liquid at the terminal stage of the solidification path. Therefore, from a welding metallurgical perspective, homogeneous Cu distribution and minimization of Cu segregation within the fusion zone are essential for suppressing or minimizing the solidification cracking susceptibility of Cu?steel dissimilar laser welding.

Enhancing microstructure and mechanical properties of laser powder bed fusion-fabricated AlSi10Mg alloy through tailored friction stir processing and post-heat treatment

In this study, a series of advanced processing techniques is employed to control the internal structure and improve the mechanical properties of AlSi10Mg alloy fabricated via laser powder bed fusion (L-PBF). In the L-PBF, AlSi10Mg sheets are subjected to friction stir processing (FSP) under low heat input conditions. The main objective of this study is to eliminate microstructural defects and refine the microstructure while maintaining a high tensile strength. FSP effectively refines the grain structure but decreases the strength significantly owing to the thermal cycle. Various post-heat treatment strategies have been proposed to optimize the microstructure and strength of AlSi10Mg alloys as well as to address the strength reduction issue. Samples in different processing stages are characterized using optical microscopy (OM), field-emission scanning electron microscopy (FE-SEM), electron backscatter diffraction (EBSD), X-ray diffraction (XRD), as well as tensile and hardness tests. Notably, the FSP + direct aging (FSP + DA) treatment significantly enhanced both the ultimate tensile strength (UTS) and yield strength (YS) without compromising the ductility achieved after FSP. By applying the strengthening model, the YS contributions of the main strengthening mechanisms in the Al matrix and Si phase at different processing stages are quantitatively analyzed. The estimated YS values are in good agreement with the experimentally measured values.

Effect of process parameters on surface formation in laser welding of Al2O3 ceramic

The attainment of formability in ceramic welding presents an imposing quandary within the realm of the manufacturing industry. In this article, the laser welding of Al2O3 ceramics was carried out to compare and analyze the influence of laser power, welding speed, laser duty cycle, and other process parameters on the macroscopic morphology of the weld, weld cracking rate, and welded joint properties. The results show that Al2O3 ceramic welds have a greater tendency to cracking and that the laser power should be matched to the appropriate welding speed. When heat input increases, the weld cracking rate decreases and then increases. Ceramic welded joints with a weld cracking rate of less than 30 % and a bending strength of more than 4 MPa can be obtained when the heat input range is 17–20.5 J/mm for continuous laser welding or 20.5–24 J/mm for pulsed laser welding. In addition, under high heat input conditions, pulsed laser welding reduces the tendency for weld cracking compared to continuous laser.

Microstructure and properties of magnetic field assisted laser wire-filled welded 22MnB5 steel joints

The magnetic field-assisted laser wire-filled welding test of 1.5 mm automotive 22MnB5 steel is performed to investigate the influence of magnetic field on the microstructure and properties of the welded joints. When no magnetic field is applied, and the laser heat input is 190 J mm−1, the welded joint width and the grain size of the coarse grain region are large. Also, there is an obvious hump defect at the bottom of the weld. Under the same heat input conditions, when a 5 mT and 15 mT steady magnetic field is applied, the thermoelectric magnetic force generated by the magnetic field promoted the flow of molten pool and concentrated laser energy. It is found that the hump defect is eliminated, the width of the welded joint is reduced, the grain size of the coarse grain region is significantly reduced, and the overall hardness of the welded joint is improved. However, different magnetic induction intensities have different effects on the solid phase transformation of the weld. When no magnetic field is added, the weld center is mainly composed of granular bainite and polygonal ferrite due to the slow cooling rate of the molten pool. When the applied magnetic field is 5 mT, the center of the weld is mainly composed of brittle and hard upper bainite because the thermoelectric magnetic force stirs the molten pool and accelerates the cooling rate of the molten pool but the overall mechanical properties of the welded joint were relatively poor. At 15 mT, lath martensite and lower bainite predominate in the weld center due to the increased cooling rate of the molten pool, thereby increasing the overall mechanical properties of the welded joint. Therefore, choosing the appropriate magnetic induction intensity is critical for improving the microstructure and properties of welded joints.

Materials characterization of Ti6Al4V to NbZr1 bimetallic structure fabricated by wire arc additive manufacturing

This study investigated the microstructures and mechanical properties of a bimetallic structure (BS) of a titanium alloy (Ti6Al4V) and a niobium alloy (NbZr1) manufactured by wire arc additive manufacturing (WAAM). Three BS thin-walls were deposited with different heat input conditions: low (180 amperes (A)), medium (200 A), and high (220 A). Microstructural characterization at the interface showed that the Niobium (Nb) diffusion on the Ti6Al4V side increased as the heat input was increased. The interfacial microstructure comprised an island area and a dendritic zone with solid solutions of (β Ti and Nb) and (α + β Ti and Nb), respectively. The hardness ranged from 99 to 367 Vickers Hardness (HV), with a considerable decrease at the interface due to the migration of Nb. Maximum ultimate tensile strength of 567 MPa was achieved for the low heat input sample, and the failure occurred at the NbZr1 side. The fractography revealed intergranular and transgranular fracture morphologies, indicating a brittle failure. The results showed that the proposed BS has a good bonding strength, and neither defects (e.g., pores and cracks) nor intermetallic compounds were observed at the interface.

The influence of shoulder-workpiece clearance on channel formation during friction stir channeling at low and high heat inputs

Friction stir channeling (FSC) is a newly developed manufacturing process that can replace the traditional fabrication processes of cooling channels for heat exchangers. Regardless of its application, the size and shape of a cooling channel are fundamental to its efficiency. In FSC, clearance between the shoulder of the tool and the workpiece top surface is a prime factor that significantly influences channel size and shape. This study examined the effect of clearance on channel characteristics using two different clearance values, 0.8 mm and 1.2 mm, respectively. The process parameters are chosen in such a way that the effect of clearance can be understood under low and high heat input conditions on several characteristics. These include channel geometry, dimensions, roof thickness, the roughness of the internal surface of the channel walls, and their topography. A rectangular channel geometry with a larger height and width was found to form at 1.2 mm clearance with high heat input parameters. Lower clearance at low heat input resulted in a successful channel, but a higher clearance value produced a defective channel for the same parameters. In conclusion, the results demonstrate how clearance and the amount of heat input are co-dependent to produce a channel with enhanced characteristics that may directly influence the performance of a cooling channel in various heat exchanger applications.

Thermal surrogate model for spacecraft systems using physics-informed machine learning with POD data reduction

Thermal analysis of spacecraft systems is one of the most critical processes in the design and operation of space missions. However, it is computationally costly to predict the temperature under all conditions including attitude, orbit, or all combinations of equipment use cases. This study proposes a novel surrogate model for full-scale thermal models using data reduction via proper orthogonal decomposition and physicsinformed machine learning. The prediction accuracy of the proposed method is evaluated using two types of thermal mathematical models to investigate the dependency of the training dataset and the size of the models. In addition, the prediction accuracy and training cost were compared between data-driven machine learning and physics-informed machine learning. As a result, the proposed method successfully predicted the full model temperature for both models under various heat input conditions. Moreover, the proposed method decreased the total training cost by 26% to 81% compared to data-driven machine learning.

Modeling of solid-air multi-dendrite growth evolution driven by coupled thermal-solute using non-isothermal quantitative phase field method

The safety hazard posed by residual or infiltrated air condensing into external oxygen-rich solid-air (SA) particles in the liquid hydrogen container deserves attention. In this study, the patterns of morphological evolution, oxygen solute distribution, and growth rate of SA single- and multi-dendrite under various thermal environments are investigated using a non-isothermal quantitative phase field model for the first time. The lattice anisotropy problem of six-fold symmetric dendrites is effectively avoided. The results show that the Type II boundary condition is more suitable for the simulation of dendrite growth, which can avoid the influence of boundary conditions on dendrite growth. In addition, the suitability of the isotropic difference method for simulating the growth of SA multi-dendrites with six-fold symmetry is verified in this paper. The maximum values of solid fraction and oxygen solute concentration within the simulated domain are 0.62 and 0.435, respectively, for an initial subcooling degree of 4 K. The temperature distribution is significantly altered by the application of boundary heat flux and affects the growth pattern of SA dendrites. Compared to the scenario with no boundary heat flux, unilateral heat input and heat extraction decreased the solid fraction of SA dendrites by 31% and increased it by 43%, respectively, while the maximum concentration of oxygen solute was reduced to 144.8% and 97.3%, respectively. When boundary heat flux was applied to all quadrilateral boundaries, the solid fraction under heat extraction and heat input conditions is reduced by 82% and enhanced by 138%, respectively, compared to the scenario with no boundary heat flux. Additionally, the maximum concentration of oxygen solute is found to be 197.6% and 69.5% of that without boundary heat flux, respectively. This study improves the understanding of the evolution of solid-air dendrite growth and can provide theoretical guidance for the safe use of liquid hydrogen systems.

Influence of welding parameters on the interface temperature field of TC4 titanium alloys/304 stainless steel friction stir lap joints

Abstract The welding parameters optimization of TC4 titanium alloys/304 stainless steel (TC4/304 SS) by friction stir lap welding (FSLW) based on orthogonal test was researched. The results show that when the rotating speed was constant, the area of the high temperature zone and the peak temperature decreased with the increase of the traversing speed; when the traversing speed was constant, the area of the high temperature zone and the peak temperature increased with the increasing rotating speed. Among them, under the condition of low heat input, the interface temperature was about 912 °C, the material at the interface cannot fully react, and there was no formation of a large amount of brittle and hard intermetallic compounds; under the condition of medium heat input, the interface temperature was about 930 °C, this temperature caused a large amount of brittle and hard intermetallic compounds at the interface; under high heat input, the interface temperature was about 975 °C, a large number of intermetallic compounds were not formed at the interface.