Cyclic Thermal Stress Research Articles

Study on the effect of variable laser power on residual stress distribution in laser directed energy deposition of Ti6Al4V

In the laser directed energy deposition (LDED) process, cyclic thermal stress loading induces significant temperature variations on the surface and subsurface of the workpiece during repeated heating, leading to the formation of residual tensile stress during cooling. This adversely affects the mechanical properties of the parts, causing deformation and defects. In this study, a heat transfer model and a three-dimensional stress model were established based on finite element analysis. A variable laser power (VLP) deposition strategy was proposed to dynamically simulate the temperature and stress fields of Ti6Al4V titanium alloy under different deposition strategies. The model was validated by collecting substrate temperature variations using thermocouples and measuring residual stress with an X-ray diffractometer (XRD). Experimental results showed that the temperature error between the simulation and the experiment ranged from 6.25 % to 10.12 %, with an average stress simulation error of 6.92 %. Among the four strategies, the samples using the VLP strategy showed a reduction in the average substrate temperature by 12.68 % to 15.08 % compared to the other three strategies. The maximum principal stress in the layer was reduced by 7.8 % to 32.14 %, and the residual stress distribution was more uniform in all directions. The microstructure of the deposition layer further indicated that the VLP strategy improves residual stress distribution and leading to better deposition quality.

Enhanced thermomechanical fatigue resistance in W10Re alloys: Microstructural and surface engineering approaches

Thermomechanical fatigue of refractory metals is commonly observed in high-temperature environments like first walls and divertors for proposed fusion reactors or X-ray anodes for medical imaging. Typically, alloying with rhenium or optimized microstructures are employed to counteract or delay the detrimental effects of fatigue in tungsten. Additionally, a novel concept is the utilization of surface structures to compensate cyclic thermal stresses. This work aimed to investigate the combination of these approaches, by comparing two W10Re alloys with vastly different microstructures, as well as engineered surface conditions of varying scales. Samples were subjected to thermocyclic fatigue under pulsed electron beam exposure, mimicking the surface temperatures typically encountered in a rotating X-ray anode. Analysis of several in-situ data streams, post-mortem investigations by metallography, and finite element methods revealed the interplay between microstructure and surface modifications. The columnar microstructure exhibited higher resistance to severe surface damage compared to the globular one, linked to the deflection of cracks along grain boundaries and subsequent melting. Coarse structuring was found to partly relieve the surface stresses during thermal cycling, preventing most of the damage accumulation. A full damage relief and performance equivalence between columnar and globular microstructure was achieved by engineering fine-structured surfaces, which led to a ten-fold increase in fatigue resistance over the non-structured condition.

Physical model investigation of a hybrid GRS integral bridge abutment under cyclic thermal stresses

GRS integral bridge abutments develop large lateral earth pressure on the facing during seasonal/diurnal thermal expansion/contraction, causing significant surface settlements. To mitigate these issues, researchers prefer the use of different kinds of facing to withstand lateral pressure in conjunction with reinforcing of backfill to reduce surface settlement. The present research investigates the performance of a hybrid integral abutment under lateral movement of the facing due to cyclic thermal expansion/contraction of the bridge deck through scaled down 1 g physical model tests. Using the optimized facing and reinforcement configuration, an integral abutment model was proposed and analyzed under varying rate of loading and different loading offsets for three displacement modes till 100 cycles of excitation. The assessment included the development of lateral pressure on facing, surface settlement, magnitude and location of peak reinforcement forces, followed by evaluating long-term performance in terms of permanent strains, stiffness degradation, and strain energy dissipation. The observations revealed that the proposed model having strong connection between the reinforcement and facing along with inclusion of secondary reinforcements along the entire height of abutment in the bearing zone exhibits rapid dissipation of accumulated strain energy, leading to a 48 % reduction in surface settlement under cyclic thermal stresses.

Effects of Fatigue Parameters on Fatigue Crack Growth Rate of Pipe Steels and Girth Weld

Abstract Oil and gas pipeline steels and welds are subjected to a wide variety of cyclic loadings: internal pressure variation, pulsation of gas pressure resulting from the cyclic operation of a reciprocating compressor at a gas compressor station, internal flow-induced vibration resulting from the turbulent flow within the pipe, vortex-induced vibration of a free-spanning section exposed to air (wind) for aboveground pipelines or water for water-crossing pipelines, and cyclic thermal stresses developed by significant changes in temperature due to seasonal changes or changes in operating temperatures. These cyclic loadings are very variable and complex. Considering the fatigue situations, a better understanding of the effects of fatigue test parameters on fatigue behaviors of pipeline steels and welds is required. Hence, in this study, the influences of fatigue test parameters on the Paris law coefficients were studied for pipeline steels and welds. It was analyzed for pipe steels of X65∼X100 and a girth weld of X70. Influences of material strength, crack orientation relative to the pipe axis, and frequency in the range of 1∼30 Hz were insignificant. It was found that the coefficients a1 and b2 of the m-ln(C) relationships linearly relied on the load ratio. The constants (α1, β1, α2, and β2) of these linear relationships between R-ratio and a1 (and b2) were determined for pipe steels.

Real-Time Rotor Ground Fault Protection Based on the Convolution Integral for Synchronous Motors With Static Excitation

The detection of motor failures is a very active research topic within the literature. In particular, ground faults in wound rotors of synchronous motors have a relatively high failure rate since the rotor winding is exposed concomitantly to electrical, mechanical, and thermal stress cycles. Its detection depends on the grounding type of the electrical power system, and, in its early stages, it may present significant resistance. This manuscript provides a new rotor ground fault protection method based on the convolution integral of the neutral voltage that is measured by a single extra sensor. In addition, it is able to fill out the gaps of the current state-of-the-art, such as: provides a larger detection frontier for incipient faults; has low sensitivity for dynamic variances of the firing angle, allowing its utilization in cyclical applications; and can be implemented in power electronic controller systems with limited bandwidth. In this sense, mathematical modeling, simulations and experimental data are presented to support to the proposed method. Furthermore, it was implemented in the controller of static excitation converters for real-time protection and successfully tested with synchronous motors (2.4MW/3.3kV) of a cold rolling mill plant owned by ArcelorMittal Group.

Numerical Simulation-Based Study on the Microstructure of TC4 Titanium Alloy in CMT Additive Manufacturing

This thesis explores the thermal and mechanical phenomena occurring during the Cold Metal Transfer (CMT) additive manufacturing process of TC4 titanium alloy. The investigation delves into the effects of layer-by-layer deposition on the thermal cycles, stress distribution, and microstructural evolution of the additive manufactured specimens. Key findings include the identification of thermal accumulation with increasing deposition layers, leading to a decrease in cooling rates and a slight increase in the peak molten pool temperatures. The temperature profiles on the substrate exhibit cyclic patterns of peaks and troughs, which become smoother and exhibit less variance between maximum and minimum temperatures as deposition progresses. Stress analysis reveals that equivalent stress within the deposited layers decreases with the number of layers. This is attributed to the thermal stress accumulation and stress cycles induced by multiple thermal cycles, which initially increase the equivalent stress. However, a reduction in cooling rates over time and the effects of remelting facilitate the release of interlayer stress, resulting in minimal residual stress within the cooled specimens. Microstructurally, the TC4 titanium alloy specimens are characterized by the presence of primary β phase spanning across multiple deposition layers, growing in the direction of additive manufacturing. The accumulated heat input from increased layering enhances the growth of the primary β phase.The specimens' microstructure features a basketweave pattern comprised of α' martensite, α, and β phases, with α' martensite directly transformed from the primary β phase. Repeated heating cycles foster diverse pathways for the secondary α phase's formation, leading to more pronounced, directionally parallel α phases and extensive basketweave structures within the specimen layers. Higher temperature gradients at specimen edges encourage the formation of needle-like α' martensite. This thesis contributes to the understanding of the thermal behavior, stress dynamics, and microstructural characteristics in TC4 titanium alloy during CMT additive manufacturing, highlighting the interplay between process parameters, thermal management, and material response.

RELAP5/Mod3.3 thermal-hydraulics characterization of the steam generator mock-up during operational transients in STEAM facility in support of the design of the DEMO WCLL BoP

The Water Cooled Lithium Lead Breeding Blanket (WCLL BB) is a key candidate for the driver blanket of the European DEMO reactor, progressing toward its Conceptual phase by the end of 2027. To assess different water and lithium-lead technologies for the WCLL BB and Balance of Plant (BoP) systems, the Water-thermal-HYDRAulic (W-HYDRA) experimental platform is under development at the ENEA Brasimone Research Centre. Among the facilities constituting the new W-HYDRA multipurpose infrastructure, STEAM is going to experimentally investigate the DEMO WCLL BoP thermal-hydraulics, focusing on the Steam Generator (SG) of the Primary Heat Transfer Systems (PHTS), to qualify its performances and suitability under its unconventional operation. The paper aims at supporting the thermal-hydraulic characterization of the Steam Generator mock-up during the sudden power variations typical of a pulsed fusion reactor. The analyzed selected scenario is the operational transient dwell-pulse-dwell, which determines high thermal cycling and correspondent high thermo-mechanical stresses on the primary side components. Two control logics with their relative drawbacks have been analyzed with a RELAP5/Mod3.3 1-D model, the first regulating the primary side average temperature, the second monitoring the minimum one. The comparison of the two systems highlighted that neither approach leads to hazardous conditions for the facility. However, while the average temperature controller is characterized by reduced thermal stresses on the components, the minimum temperature controller is characterized by higher thermal gradients for the primary loop. Both methodologies will be tested in the dedicated experimental campaign, aiming at yielding insights and evaluations concerning control strategies applicable to the DEMO reactor.

Numerical analysis of thermal differential distribution in Bobbin tool friction stir welding of 7075-AZ31B dissimilar alloy

The theoretical model of bobbin tool friction stir welding (BT-FSW) structure and dynamic process is established. Because of the great differences in properties of different materials, the mathematical relationship between material stress and deformation will be expressed based on 3D transient heat conduction equation and J-C constitutive model. The BT-FSW process of 7075 and AZ31B was analyzed by finite element method, and the field distribution, thermal cycle curve and stress distribution characteristics of different welding areas of the welded material were simulated. To predict and control the non-equilibrium distribution of welding temperature and stress field, the influences of different Rotating speed, welding speed, offset and other variables on the BT-FSW process of 7075/AZ31B aluminum magnesium dissimilar alloy were studied comprehensively. Finally, the reliability of the model is proved by fitting the experimental and numerical analysis results. The research results show that the temperature of BT-FSW presents an “hourglass” symmetrical distribution, and the stress distribution on both sides of the plate is uniform when the aluminum alloy is placed on the advancing side, the stirring tool is offset to the aluminum alloy by 2mm, and the rotating speed and welding speed are 700r/min and 180mm/min, respectively.

Interfacial Crack Growth-Based Fatigue Lifetime Prediction of Thermoelectric Modules under Thermal Cycling.

As a result of the complexity and difficulty of the lifetime assessment of the thermoelectric (TE) module, the related research is still immature. In this work, to predict the lifetime of the Bi2Te3-based TE module from the perspective of cyclic thermal stress leading to interface cracking, the viscoplastic behavior of the solder layer is first described by the Anand material ontology model, and then the sprouting and expansion of interface cracking of the module are simulated by combining the Darveaux model and the viscoplastic dissipation energy accumulated during the thermal stress cyclic loading. After that, the complete lifetime prediction model of the TE module is established on the basis of the thermal cycling experiments and the finite element simulation calculation data, which can simply and efficiently predict the cycle number of the module resistance rise and its rise rate. The prediction deviations are 6.1 and 6.7%, respectively, verifying the feasibility of the model. The work in this paper can provide a reference for the life evaluation of TE modules.

Cyclic Oxidation Kinetics and Thermal Stress Evolution of TiAl Alloys at High Temperature

The oxidation resistance of TiAl alloys is crucial for their commercial application. In this paper, a cyclic oxidation test with stable air circulation was designed to investigate the cyclic oxidation behavior of the TNM alloy and 4822 alloy at 800 °C and to analyze the phase, morphology, and thermal stress evolution of the oxide layer. The oxidation weight gain curves of both alloys are found to be in parabolic form, and the oxidation reaction orders of the TNM alloy and 4822 alloy are 2.374 and 1.838, respectively. The Nb and Mo elements enhance the antioxidant performance of the TNM alloy by inhibiting the dissolution and diffusion of oxygen, Ti, and Al atoms in the TiAl alloy. The thermal stress evolution of the two alloys during the heating and cooling phases of the cyclic oxidation process are calculated separately, and it is found that the thermal stresses in the TNM alloy are smaller than those in the 4822 alloy, while the maximum thermal stresses appear at the oxide/substrate interface rather than inside the oxide scale, which quantitatively explains the oxidation peeling resistance of the two alloys.

Improving Reliability of Fan -Out Wafer Level Package Through Doping of Lead-Free Solder Balls

Embedded wafer level ball grid array (eWLB) or FO-WLP (Fan-out wafer-level packaging) is investigated as a package for MMICs (Monolithic Microwave Integrated Circuit) for automotive radar applications in the 77GHz range. Doping of Bi and/or Sb was applied to improve the resistance of lead-free SAC balls against thermal cycling stress. We have shown that by increasing the doping level the lifetime can be increased and determined the maximum doping level before extrinsic failure modes dominate. It is well-known from the literature that doping of Bi and/or Sb improves the resistance of lead-free SAC balls against thermal cycling stress. It was shown that lifetime of FC-BGA package can be multiplied using Bi and/or Sb doping. The lifetime gain is achieved by reduced creepage of the hardened balls caused by the doping. This reduced creepage increases the risk of causing other failures than ball cracks in the eWLB package or the PCB during thermal cycling stress. We have tested robustness of 7x8,5 mm^2 eWLB packages against thermal cycling stress T = -40 to 125 °C using SAC-balls with different Bi-doping content from 0% to 2,5% Bi concentration. As could be expected the solder ball fatigue mode is delayed more and more increasing the Bi content. We found other failure modes than solder ball fatigue emerging at doping around 1%. The fatigue modes are shifted towards cupper lines on PCB or into the package. Cu line cracks can be overcome by switching the PCB layout from NSMD (non solder-mask defined) to SMD (solder-mask defined) solder pads. In general there is a lifetime penalty when switching from NSMD to SMD, but by avoiding the Cu line cracks this lifetime loss is overcompensated using SMD pads for optimum performance. As input for simulations we have characterized the doped solder material using specimens produced in glass columns. We have also tested the components on PCBs with different top layer laminate with different CTE and elastic modulus to assess the influence of the PCB properties on the lifetime. It is a trend in automotive radar systems to use stiffer laminates which are cheaper but have negative influence on component lifetime. Solder ball shear tests were also carried out to characterize the influence of ball doping on other board-level reliability beyond thermal cycling performance. As expected ball shear force is increased with increased doping level. At increased shear-force the shearing is still done through the solder ball and does not lead to different shear-mode. Finally drop-tests were done to check influence of doping on board-level reliability performance other than thermal-cycling performance.

Prognosis of Li-ion Batteries Under Large Load Variations Using Hybrid Physics-Informed Neural Networks

The development of new modes of transportation such as electric vertical takeoff and landing aircraft and the use of drones for package and medical delivery have increased the demand for reliable and powerful electric batteries. Therefore, accurately predicting the degradation of a battery’s state-ofhealth (SOH) and state-of-charge (SOC) is a crucial albeit still challenging task. There is a need for models that can accurately predict the SOH and SOC while taking into account the specific characteristics of a battery cell and its usage profile. While traditional physics-based and data-driven approaches are used to monitor the SOH and SOC, they both have limitations related to computational costs or that require engineers to continually update their prediction models as new battery cells are developed and put into use in battery-powered vehiclefleets.Battery capacity degradation can vary from battery to battery and can also be influenced by changes in load due to internal thermal stress. While sophisticated electrochemistry-based models can provide precise predictions of the SOC during adischarge cycle when parameters are well-tuned, using highfidelity models for prognostics purposes can be computationally expensive. Those models also require tuning to specific battery types and at times to specific specimens, thus hindering generalization. In contrast, purely data-driven approaches can learn the relationship between input and output for SOC prediction based on load input, but they require a large and diverse training dataset and lack any physical or electrochemical understanding, making far-ahead predictions challenging if test loading conditions fall outside the training distribution. To address some of the drawbacks of the aforementioned modeling approaches, in this paper, we enhance a hybrid physics-informed machine learning version of a battery SOC model we presented in previous work to predict voltage dropduring discharge. The enhanced model captures the effect of wide variation of load levels, in the form of input current,which causes large thermal stress cycles. The cell temperature build-up during a discharge cycle is used to identify temperature-sensitive model parameters. Additionally, we enhance an existing aging model built upon cumulative energy drawn by introducing the effect of the load level. We then map cumulative energy and load level to battery capacity with a Gaussian process model. To validate our approach we use a battery aging dataset collected on a self-developed testbed, where we used a wide current level range to age battery packs in accelerated fashion. Prediction results show that our model can be successfully calibrated and generalizes across all applied load levels.

A Fatigue Lifetime Prediction Model for Aluminum Bonding Wires

Electrical signal transmission in power electronic devices takes place through high-purity aluminum bonding wires. Cyclic mechanical and thermal stresses during operation lead to fatigue loads, resulting in premature failure of the wires, which cannot be reliably predicted. The following work presents two fatigue lifetime models calibrated and validated based on experimental fatigue results of an aluminum bonding wire and subsequently transferred and applied to other wire types. The lifetime modeling of Wöhler curves for different load ratios shows good but limited applicability for the linear model. The model can only be applied above 10,000 cycles and within the investigated load range of R = 0.1 to R = 0.7. The nonlinear model shows very good agreement between model prediction and experimental results over the entire investigated cycle range. Furthermore, the predicted Smith diagram is not only consistent in the investigated load range but also in the extrapolated load range from R = −1.0 to R = 0.8. A transfer of both model approaches to other wire types by using their tensile strengths can be implemented as well, although the nonlinear model is more suitable since it covers the entire load and cycle range.

Study on creep-fatigue life of ODS-Cu as heat sink in divertor PFU

In fusion devices, the actively cooled W-monoblocks of the PFUs (Plasma Facing Units) are installed in the divertor to protect the vacuum vessel and magnets against neutron flux in the bottom region of the vessel. Copper alloy is considered to be the ideal heat sink material due to its high thermal conductivity and sufficient mechanical strength, in which ODS (oxide dispersion-strengthened)-Cu is selected as a candidate. With the increasing of operating parameters, such as higher heat flux (∼20 MW/m2, H-mode) and longer pulse (up to 2.00 h) in EU-DEMO [1], the heat sink structure will undergo thermal creep induced by high temperature, stress and long holding time, which accelerates fatigue failure and could potentially be a very critical issue for the long-term safe operation of the fusion reactor. In this paper, an ITER-like monoblock with ODS-Cu as heat sink was studied for its creep fatigue life under DEMO operation conditions. The temperature distribution and stress/strain results of ODS-Cu were determined using finite element analysis. The investigation shows that high temperature creep occurs at the heat sink. Based on a damage accumulation model, the predicted life of the PFUs for the divertor are investigated at different operating modes. The analysis provides theoretical feasibility for selecting ODS-Cu as a heat sink material. The effect of stress relaxation on creep behavior during thermal stress cycle was also demonstrated and this was compared with the same for CuCrZr.

Comparative Analysis of PEDOT and ITO Under Thermal Bending and Cycling Stresses: Implications for Flexible Solar Cells

Poly(3,4-ethylenedioxythiophene) (PEDOT) and Indium Tin Oxide (ITO) are widely used in electronic devices, but their stability under thermal stress is a concern. Both PEDOT and ITO are susceptible to thermal stress, but their stability depends on the temperature and duration of exposure. To ensure long-term stability, it is essential to use appropriate thermal management techniques and stable materials. ITO has good mechanical stability under stretching and bending, while PEDOT can withstand high strains. Flexible solar cells are exposed to heating-cooling cycles, and when the thin film and substrate expand at different rates, residual strains caused by the thermal mismatch occur. ITO is heavily used in flexible solar cells, but indium is scarce and expected to run out within 50 years. PEDOT is a candidate to replace ITO and is currently under intensive research. This paper compares the thermal stability of PEDOT and ITO under thermal bending and cycling stress. In order to investigate the significance of different factors on thin film electrical characteristics, the DOE (design of experiments) tool was used for data collection and analysis of variance was used to analyze the data. The results showed that PEDOT is better than ITO under cyclic bending loading, while ITO is slightly more stable than PEDOT under thermal stress. These findings provide new insights into the behavior of PEDOT and ITO under thermal stress and their potential applications in electronic devices.

Intergenerational plasticity to cycling high temperature and hypoxia affects offspring stress responsiveness and tolerance in zebrafish.

Predicted climate change-induced increases in heat waves and hypoxic events will have profound effects on fishes, yet the capacity of parents to alter offspring phenotype via non-genetic inheritance and buffer against these combined stressors is not clear. This study tested how prolonged adult zebrafish exposure to combined diel cycles of thermal stress and hypoxia affect offspring early survival and development, parental investment of cortisol and heat shock proteins (HSPs), larval offspring stress responses, and both parental and offspring heat and hypoxia tolerance. Parental exposure to the combined stressor did not affect fecundity, but increased mortality, produced smaller embryos and delayed hatching. The combined treatment also reduced maternal deposition of cortisol and increased embryo hsf1, hsp70a, HSP70, hsp90aa and HSP90 levels. In larvae, basal cortisol levels did not differ between treatments, but acute exposure to combined heat stress and hypoxia increased cortisol levels in control larvae with no effect on larvae from exposed parents. In contrast, whereas larval basal hsf1, hsp70a and hsp90aa levels differed between parental treatments, the combined acute stressor elicited similar transcriptional responses across treatments. Moreover, the combined acute stressor only induced a marked increase in HSP47 levels in the larvae derived from exposed parents. Finally, combined hypoxia and elevated temperatures increased both thermal and hypoxia tolerance in adults and conferred an increase in offspring thermal but not hypoxia tolerance. These results demonstrate that intergenerational acclimation to combined thermal stress and hypoxia elicit complex carryover effects on stress responsiveness and offspring tolerance with potential consequences for resilience.

Improving the anti-thermal-shock properties of Sc2O3-Y2O3-ZrO2-CaF2-PHB abradable coatings by fabricating the textures on ceramic matrix composites: experiment verification and numerical analysis

The abradable coating is one of the most important coatings for improving the efficiency of aeroengine. To improve the durability of Sc2O3-Y2O3-ZrO2-CaF2-PHB abradable coating under the conditions of high temperature thermal shock, the femtosecond laser processing technology is proposed to fabricate the texture on the surface of SiCf/SiC composites to improve the coating/matrix contact area. The environmental barrier coating (EBC) was prepared by vacuum plasma spraying (VPS) equipment on SiCf/SiC ceramic matrix composites to avoid water-oxygen corrosion. And the abradable coating was prepared by air plasma spraying (APS) equipment on the EBC. The thermal shock test of the abradable coating at (1,250 ± 50)°C was established in the simulated gas environment of the oxygen-propane flame, and the variation of interface stress between the layers during the thermal shock test was analyzed by ANSYS software. The hidden crack between the layers was detected by an infrared thermal imager. The results show that the surface textures have significant influences on the anti-thermal-shock properties of Sc2O3-Y2O3-ZrO2-CaF2-PHB abradable coating by improving the contact area and optimizing the interface stress distribution. The bonding strengths of the coating are increased by 14.6% and 42.2% when the surface textures increase the contact area of the substrate and the coating by 41.3% and 104%, respectively. Compared with the coatings without texture treatments, the coatings with texture treatments can reduce coating thickness by 30% and the coatings do not peel off after the thermal shock tests. Influenced by the cyclic thermal stress, the cracks of abradable coating are initiated at the defect position and gradually propagated a shell-like shape. The textures on the surface of SiCf/SiC composites have deep influences on improving the high-temperature thermal shock life of Sc2O3-Y2O3-ZrO2-CaF2-PHB abradable coating.

Transformation of carbides and mechanisms for cracking in Co-based alloy surfacing layer during thermal fatigue

A fantastic metallurgical bond of Stellite 6# Co-based alloy/FB2 steel joint was achieved using gas tungsten arc welding, and thermal cyclic tests were employed to investigate the initiation and propagation of cracks, and the microstructure evolution in the weldments. Multiple cracks with the length over 10 μm were found after 300 cycles of thermal fatigue (TF), and the detail microstructure of Stellite 6# layer before and after TF was investigated. Results showed that the thermal cycling led to the accumulation of thermal cyclic stress, coarsening of eutectic carbides, generation of laves phase and transformation of Co phase, which influenced the initiation and propagation of cracks. More specifically, the initiation of the cracks was attributed to newly generated W-rich laves phase in addition the with the accumulation of thermal cyclic stress, while Cr atoms, together with O and W atoms, were distributed near the cracks, and acted as the crack propagation path. Finally, the martensitic transformation of γ-Co to ε-Co, driven by the plastic deformation at the crack tip, could also in turn help to crack propagation.

Methodology for Creating a Software for Structuring the Reconstruction Technologies by Laser Welding of Metal Moulds

Abstract Metal and plastic parts are made in moulds, in production processes such as plastic injection, metal alloy die casting and metal deformation. During operations, moulds are exposed to severe conditions: wear, impact, corrosion, thermal cycling and high mechanical stresses. Moulds reconstruction has advanced, precisely because to new technologies, such as laser welding. Laser technologies offers several benefits, including increase of work speeds, reduced thermally influenced zones and material losses and decreased additional working times for mechanical machining processes.

Accelerated Stress Testing of Perovskite Photovoltaic Modules: Differentiating Degradation Modes with Electroluminescence Imaging

Herein, electroluminescence (EL) and thermal imaging are used to examine p–i–n metal halide perovskite (MHP) photovoltaic (PV) mini‐modules (MA0.6FA0.4PbI3, 20 cells, 78 cm2) before and after indoor‐accelerated stress testing or outdoor deployment. Distinct spatial patterns in the EL images emerge, which depend on the external stress conditions experienced by the mini‐module. Imaging results highlight a distribution of dark speckle features that dominate after UV stress, attributed to widespread interfacial contact degradation. Lateral intensity gradients across cells dominate after thermal cycling (TC) stress, attributed to current crowding near scribe defects. While current–voltage analysis alone does not give full insight on the degradation process, this study shows that distinct degradation modes can be further defined by multimodal electro‐optical imaging (i.e., EL combined with photoluminescence and dark lock‐in thermography). Neither UV exposure nor TC‐accelerated stress testing alone replicates the same degradation signatures observed after outdoor deployment, suggesting that multiple degradation modes occur under concurrent stressors outdoors. Spatial characterization of degradation modes in MHP PV mini‐modules before and after accelerated stress testing lays the groundwork for developing targeted accelerated stress testing procedures through comparison with outdoor aging.