Thermo-mechanical Simulator Research Articles

Variable plate kinematics promotes changes in back-arc deformation regime along the north-eastern Eurasia plate boundary

The stretching of the lithosphere leading to back-arc basins formation generally develops behind arc-trench systems and is considered the consequence of slab retreat relative to the upper plate. Here, we examine the deformation regime evolution within the overriding plate due to subduction processes, using thermo-mechanical numerical simulations. We explore the north-eastern Eurasia plate boundary and the mechanisms of subducting Pacific plate since 57 Ma. During this time interval, several extensional basins formed along the Eurasia margin, such as the East China Sea, the Japan Sea, and the Kuril basin. Here, we increased the simulation complexity, with the inclusion of (i) the kinematic variability of the Pacific plate over the geological past with respect to a fixed Eurasia, incorporating time-dependent (i.e., temporally evolving) velocities computed from plate motion reconstructions; (ii) a Low-Velocity Zone within the asthenosphere, and (iii) a horizontal eastward mantle flow. Our results show a crucial role of the mantle flow for the development of lithospheric extension and back-arc basin opening, and a main kinematic control of the subduction trench position, which advances and retreats, into distance intervals in the order of ∼\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\sim$$\\end{document} 100 km, and providing stages of compression and extension in a back-arc basin.

Effect Mechanism of α-Ferrite Sustained Precipitation on High-Temperature Properties in Continuous Casting for Peritectic Steel

Exploring the mechanism of the α-ferrite precipitation process on high-temperature properties plays an important guiding role in avoiding slab cracks and effectively regulating quality. In this work, in situ observation of the α-ferrite sustained precipitation behavior for peritectic steel during the austenitic phase transition process has been investigated using high-temperature confocal scanning laser microscopy. Meanwhile, the high-temperature evolution of the phase fractions during the phase transition process was quantitatively analyzed based on the high-temperature expansion experiment using the peak separation method. Furthermore, the high-temperature properties variations of the casting slab during the α-ferrite sustained precipitation process were investigated with the Gleeble thermomechanical simulator. The results show that the film-like ferrite precipitated along the austenite grain boundaries at the initial stage of phase transition, then needle-like ferrite initiates rapid precipitation on film-like ferrite when the average thickness reaches 15~20 μm. Hot ductility reached a minimum at the ferrite phase fraction fα = 10~15%, while high-temperature properties returned to a higher level after fα > 40~45%. The appearance of a considerable amount of needle-like ferrite and grain refinement effectively improves the high-temperature properties with the α-ferrite precipitation process advances.

Thermo-Mechanical Analysis of MYRRHA Fuel Pins Irradiated in the TRIGA Annular Core Pulse Reactor of ICN Pitesti

MYRRHA represents an innovative and unique facility designed to demonstrate the feasibility of the ADS concept at reasonable power levels and to pave the way towards the next generation of nuclear reactors. At the same time, this versatile infrastructure aims to support the ALFRED reactor. In the framework of investigating MYRRHA fuel pin thermo-mechanical behavior during transient conditions, the TRANSURANUS fuel performance code along with ANSYS, were used for thermo-mechanical simulations on three experimental fuel pins containing UO2 pellets and 15-15Ti clad, surrounded by stagnant LBE coolant, irradiated in the ACPR-TRIGA reactor at ICN Pitesti. The results concern both fuel and cladding performance and are compared with the available experimental data.

Numerical assessment of welding sequences in single-pass pipe welding for minimizing residual stresses

This research aims to investigate the impact of different welding sequences in the circumferential direction on the welding process of 304 stainless steel pipes. A fully coupled transient thermo-mechanical simulation technique used to numerically replicate welding behaviour on a single-pass butt-welded cylinder joint with a nominal diameter of 300 mm and a thickness of 8.38 mm. Five distinct welding sequences are considered, and temperature profiles are measured at four circumferential positions. The findings reveal that the residual stresses within and near the weld deposit are indeed influenced by the chosen welding sequence. In case 1, the value of maximum temperature reached 1840 Degree K at point T4, achieving equilibrium between the flux input and heat losses during welding. In case 3, the maximum temperature value (1530 Degree K) is lower than all other cases due to better heat distribution. Respective to the temperature distribution the maximum stress values in case-1 to 5 are 211, 201, 138, 146, and 147 Mpa. Based on a comprehensive analysis of these factors, case 3 emerges as the preferable welding sequences for pipes falling in the NPS 10 to NPS 24 size category.

Thermal corrosion fatigue crack growth behavior and life prediction of 304SS pipeline structures in high temperature pressurized water

The influence of transient water temperature changes on the fatigue crack growth behavior of 304SS pipeline structures was studied based on high-throughput testing method through the modification of dual loop circulating water equipment. Results demonstrated that the fatigue crack growth rate gradually decreased with the decrease of cooling rate, and the crack growth rate was exponentially related to the cooling rate. Both the base material and weld of the stepped pipe showed a transgranular cracking mode, and propagated continuously by slip-oxidation mechanism. Compared with the fine equiaxed grain of the base material, the grain in the weld was coarse and the residual strain was large, and the crack growth rate of the weld was obviously higher. Then, the thermal fatigue crack growth rate model for stepped pipes was established by combining finite element thermo-mechanical coupling simulation and three-dimensional crack propagation analysis software, and the model was modified based on the experimental results.

Measurement and Simulation of Mechanical Strength of Back-End-Of-Line Layer in Advanced CMOS Dies

The back-end-of-line (BEOL) layers of ICs are subjected to considerably high mechanical forces during processing and when operating in harsh conditions. Without proper design and flip chip process control, the forces induced from flip chip bumps may exceed the ultimate strength of the BEOL resulting in critical failures. It is therefore of high interest to have a measurement method to quantify the strength of the BEOL structure of a functional IC. Ultimate fracture stress values are extracted from these measurements which can be used in thermo-mechanical simulations of flip chip assemblies for survivability evaluations.

Modelling and simulation of heat flow in indexable insert drilling

In machining, the heat generated during the process deforms the components and the final shape might not meet specified tolerances. There is therefore a need for a compensation strategy which requires knowledge of the workpiece temperature field and the associated thermal distortions. In this work, a methodology is presented for the determination of the heat load for indexable insert drilling of AISI 4140. Compared to previous research, this work has introduced a varying heat load. The heat load is extracted from thermo-mechanical finite element simulations for different nominal chip thicknesses and cutting speeds using the coupled Eulerian-Lagrangian formulation of an orthogonal turning process. The heat load is then transferred to a simplified 2D axisymmetric heat transfer model where the in-process temperature field in the workpiece is predicted. To verify the methodology, the predicted temperatures are compared to the experimentally measured temperatures for various feed rates. It is found that the model is capable of predicting the workpiece temperatures reasonably well. However, the methodology needs to be further explored to validate its applicability.

Thermomechanical and microstructural simulation of rotary friction welding process of Inconel718 alloy using the finite element method

Thermomechanical and microstructural simulation of rotary friction welding process of Inconel718 alloy using the finite element method

Self-heating and fatigue crack growth behavior of reinforced NR/BR nanocomposites with different blending ratio

Fatigue crack growth and dissipative self-heating due to viscoelasticity are crucial properties of rubber materials under dynamic service conditions. Systematic evaluation of the thermo-mechanical coupled fatigue properties with suitable lab testing methods could contribute to the development of long-lasting and robust elastomer materials. In this work, on the one hand, the hysteresis energy density, thermal conductivity, and surface temperature rise, which are closely related to the self-heating generation rate, heat transfer rate and heat build-up of the carbon black reinforced seven different natural rubber (NR) and polybutadiene rubber (BR) blends were measured. A thermo-mechanical coupling simulation method was used to reproduce the experimental observation. On the other hand, the fatigue threshold (T0), critical tearing energy (Tc), and fatigue crack growth rate (FCGR) under different tearing energy were investigated by using the advanced rubber fatigue instruments. The Lake-Lindley model was utilized to describe the rubber fatigue responses from the intrinsic strength to the ultimate strength. The results show that the dissipative self-heating of NR/BR:30/70 blend is the most obvious one, which could be well explained by the simulation results. The T0 shows an upward trend while Tc shows a downward trend with the increasing blend ratio of BR. The existence of carbon black fillers showed tiny effect on T0 of NR, but significantly enhanced the T0 of BR. The FCGR of reinforced NR/BR nanocomposites have Lake-Lindley law responses that cross over each other. Therefore, which rubber material is superior to others in resisting crack propagation depends on the magnitude of the input tearing energy.

Mesoscale modellings of axial compressive failure of geometrically-similar CFST columns at low temperatures

In this paper, a thermo-mechanical sequential coupling mesoscopic simulation method was established and verified, which considered the interaction between steel tube and meso-components of concrete due to the difference in thermal parameters, as well as the low-temperature effect on mechanical parameters. On the basis of heat conduction analysis, the damage evolution and failure mechanism of CFST column under axial compression were subsequently revealed, and the effects of low temperature (20, −30, −60 and −80 °C), cross-section size (160, 320, 480 and 640 mm), width-thickness ratio (27, 36, 53 and 107) and cross-section shape (square and circular) on axial compression performance and the corresponding size effect of CFST columns were quantitatively analysed. Research results show that the low-temperature action can enhance the nominal peak strength and residual strength of CFST column, but weaken the ductility. As the cross-section size increases from 160 to 640 mm, all the nominal peak strength, nominal residual strength and peak strain of circular CFST column decrease with the maximum reductions of 16.2, 28.7 and 16.9%, respectively. Besides, the low-temperature action can enhance the size effect on nominal peak strength of CFST column with the maximum increase of 68.8%. Whether at ambient or low temperature, the size effect on nominal peak strength of square column is stronger than that of circular one. The size effect behaviour on axial compressive peak strength at various temperatures can be also well described by the previous proposed prediction formula. The research results of this paper can provide reference for the engineering application of large-sized CFST columns in the extreme low-temperature environment.

Thermomechanical Rotor Fatigue of an Interior Permanent Magnet Synchronous Motor

Interior permanent magnet synchronous motors (IPMSMs) are extensively used as traction motors today because of their exceptional torque, power density, and wide, constant power operating range. Under real-world usage, an IPMSM rotor undergoes varying electromagnetic, thermal, and mechanical loads. Under such conditions, fatigue life-based design criteria should be used over stress-based design criteria to ensure the structural integrity of the rotor. Moreover, the driving dynamics can change the rotor temperature continuously, which affects the electromagnetic, mechanical, and fatigue properties of the rotor material. This paper proposes a robust thermomechanical rotor fatigue simulation workflow considering significant loads acting on an IPMSM rotor and the temperature variation throughout a drive cycle. It discusses an accelerated fatigue life estimation approach based on the peak valley extraction method to reduce the simulation time significantly for the stress and fatigue analysis. Then, it presents a method for a stress-life curve generation for variable loading. It also presents a sensitivity study with a median S-N curve, and a 90% reliability and 95% confidence (R90C95) S-N curve.

Research on thermal deformation of cylinder bore with orthogonal experiment method of aluminum alloy cylinder block in diesel engine

Using aluminum alloy materials provides an efficient and direct method for achieving engine weight reduction. In this study, a thermo-mechanical coupling simulation model of the diesel engine was established to investigate the deformation of cylinder bores in both cast iron and aluminum alloy cylinder blocks. The reliability of the simulation model is validated by the temperature field test of the cast iron cylinder. Four evaluation indexes, namely average roundness, cylindricity, coaxiality, and light leakage, were used to assess the deformation of the cylinder bore. The results indicate that the temperature is the primary factor contributing to the deformation in both cast iron and aluminum alloy cylinder bores. Under thermo-assembly condition, the average roundness, cylindricity, coaxiality, and light leakage rate of aluminum alloy cylinder bore were observed to be higher by 36.71 %, 12.69 %, 14.77 %, and 18.85 %, respectively, compared to those of cast iron cylinder bore. To decrease the deformation of the cylinder bore, the orthogonal experiment method was used to study the three factors affecting the heat dissipation of the water jacket. It was discovered that extending the water jacket extends upward was the most effective way to reduce the temperature of the cylinder block. By selecting the optimal combination scheme for simulation calculations, an optimized cylinder temperature of 162 °C, with the maximum deformation of the cylinder bore decreasing by 13.64 %. Additionally, the average roundness, cylindricity, coaxiality, and light leakage rate of the cylinder bore showed reductions of 17.48 %, 21.8 %, 23.00 %, and 14.10 %, respectively, when compared to the original aluminum alloy cylinder block.

Evaluation of methods used for simulation of heat-affected zones in duplex stainless steels

The weldability of duplex stainless steels partly depends on the ferritization of the high-temperature heat-affected zone (HT-HAZ). This area is rather narrow, and it can be challenging to visualize and determine its actual impact on the properties. To address this, various methods were applied to study the grain growth and austenite reformation in the HT-HAZ of the lean duplex grade UNS S32101. Thermo-mechanical Gleeble® simulations were conducted at 1360 °C with different holding times and cooling rates. Subsequently, the grain size and ferrite content were measured on polished and etched cross-sections. Bead-on-plate welds were performed on the same heat of 6-mm plate thickness using the gas tungsten arc welding (GTAW) process. The shielding gas was Ar + 0–8% N2 to illustrate the effect of nitrogen additions on the HT-HAZ morphology. The arc was either stationary, welding at one spot for 0.5–120 s, or travelling at different speeds to generate varying heat inputs and temperature gradients. The thermo-mechanical simulations approximated the results obtained by travelling arc welding and allowed for a more comprehensive investigation. Stationary arc welding was not suitable for HT-HAZ studies as it quickly caused nitrogen depletion and resulted in significantly higher ferrite contents compared to the travelling arc welds.

Residual Stress Generation in Additive Manufacturing of Complex Lattice Geometries

Residual stresses developed during additive manufacturing (AM) can influence the mechanical performance of structural components in their intended applications. In this study, thermomechanical residual stress simulations of the laser powder bed fusion (LPBF) process are conducted for both simplified (plate and cube-shaped) geometries as well as five complex lattice geometries fabricated with Inconel 718. These simulations are conducted with the commercial software package Simufact Additive©, which uses a nonlinear finite element analysis and layer-by-layer averaging approach in determining residual stresses. To verify the efficacy of the Simufact Additive© simulations, numerical results for the plate and cube-shape geometries are analyzed for convergence and compared to experimental residual stress results available in the literature. Numerical residual stress results are subsequently compared for five complex lattice geometries. Results suggest that lattice geometry can play a significant role in the distribution and magnitude of residual stresses, which are significant in some applications.

Rheology of Ti-6Al-4V alloy under non equilibrium conditions during β forging

During the “β-forging” of Ti-6Al-4V structural aircraft components that follows pre-heating above the β-transus, the skin zone of the blank actually cools down to below the β-transus whilst being deformed, as a result of heat losses towards the atmosphere or the dies. The core areas of the bulkiest sections of the blank, however, can be deformed above the β-transus during the whole processing time. This paper focuses on the development of an innovative rheological model to support the numerical modelling of the forging process, suitable for both the equilibrium conditions above the β-transus and the non-equilibrium conditions below. For that purpose, small-scale hot compression tests were performed with the thermomechanical simulator Gleeble 3500, after pre-heating in the β-field of Ti-6Al-4V at 1100 °C and rapid cooling to the compression temperature under the β-transus, which was varied between 750 °C and 950 °C. In some cases, a lag time -or stabilization time- at constant temperature was introduced between the cooling step and the deformation step. Effects of lag time and deformation temperature on microstructural evolutions and rheological properties of Ti-6Al-4V were investigated. Results show that the lack of stabilization time leads to a significant reduction of the flow stress at low strain. Such a behavior is associated with non-equilibrium thermodynamic conditions at the beginning of deformation and the progress of phase transformation during deformation. Based on that observation, an analytical formulation for the targeted rheological model is proposed. It includes a sub-model for the kinetics of phase transformation derived from the literature.

Study on hot compressive deformation behavior and microstructure evolution of G13Cr4Mo4Ni4V steel

To solve the problem of poor uniformity of microstructure of high alloy bearing steel G13Cr4Mo4Ni4V after rolling, the deformation behavior of the steel and its effect on the microstructure evolution was studied systematically. Gleeble-3800 thermo-mechanical simulator was used for precise control of deformation temperature ranging from 1000 to 1200 °C and deformation rate 0.01–10 s−1. Based on modified stress and strain curves by temperature and friction, the processing map of tested steel was drawn. Electron backscatter diffraction (EBSD) and transmission electron microscope (TEM) were used to analyze the typical microstructure and carbide properties of different hot working domains respectively. The results showed the processing map could be divided into four regions: domain A 1000–1150 °C, 0.1–10 s−1; B 1000–1100 °C, 0.01–0.1 s−1; C 1100–1150 °C, 0.01–0.1 s−1 and D 1150–1200 °C, 1–10 s−1. Domain A was characterized by incomplete dynamic recrystallization (DRX) which included fine recrystallized grains and elongated deformed grains, whose softening mechanism was mainly discontinuous DRX (dDRX) and limited DRV and continuous DRX (cDRV) related to the ferrites and carbides. For domain B, the deformed grains gradually disappear with temperature rising, instead serrated grains appear with dDRX as dominating softening mechanism. A large number of carbides hinder DRX at 1000 °C with low temperature. With the increase of temperature, carbides dissolve and DRX degree increases. Grain coarsening is obvious because of high deformation temperature and low strain rate in domain C, although the nanoscale MC type carbides prevent recrystallization grain coarsening to some extent. Completely DRX resulted in uniform and fine with defect-free deformation microstructure in domain D, whose volume fraction of recrystallization reached up to 0.96 according to EBSD results. By considering the uniformity of microstructure and the distribution of carbide comprehensively, domain D is an ideal region for hot working.

Influence of Nb/Mo Alloying on Phase Transformations and Microstructures in 0.05C-1.5Mn-Nb-Mo Microalloyed Steels during Thermomechanical Simulation

Influence of Nb/Mo Alloying on Phase Transformations and Microstructures in 0.05C-1.5Mn-Nb-Mo Microalloyed Steels during Thermomechanical Simulation

CuZn40Pb2 brass hot deformation behaviour modelling using Hansel Spittel constitutive model

ABSTRACT Due to its popularity in the industry, brass is an important material to model as it can lead to time and cost savings. The hot deformation behaviour of CuZn40Pb2 brass was performed using Hansel Spittel constitutive model. Hot compression tests were carried out at temperatures ranging from 550°C to 750°C with strain rates of 0.1/s, 1/s and 10/s using a thermomechanical simulator Gleeble. The results show that the temperature and the strain rate have a significant impact on the flow stress. The impact of friction between the specimen and anvils, as well as the effect of increasing temperature during the hot compression tests, were considered. A detailed approach was used to correct the flow curves accordingly. The constitutive model was determined based on the corrected flow curves that would be used in the forging process simulations, through FORGE. This finite element software is based on the constitutive Hansel Spittel model. A comparative study between the experimental and numerical results showed that the numerical flow curves of CuZn40Pb2, computed from the constitutive model, are in good agreement with the experimental data. It proved that the Hansel Spittel is an appropriate constitutive model to describe the hot deformation behaviour of CuZn40Pb2 brass.

Numerical Study of the Cold Metal Transfer (CMT) Welding of Thin Austenitic Steel Plates with an Equivalent Heat Source Approach

The CMT (cold metal transfer) arc welding process is a valuable joining method for assembling thin sheets, minimizing heat transfers, and reducing subsequent deformations. The study aims to simulate the CMT welding of thin stainless-steel sheets to predict temperature fields and deformations. Both instrumented tests and numerical simulations were conducted for butt-welding of sheets with a thickness of 1 to 1.2 mm. Weld seam samples were observed to identify equivalent heat sources for each configuration. The electric current and voltage were monitored. Temperature measurements were performed using K-type thermocouples, as well as displacement measurements via the DIC (digital image correlation) technique. Thermomechanical simulations, considering phase changes and the actual seam geometry induced by filler material, were conducted using an equivalent heat source approach. A unique heat exchange coefficient accounting for thermal losses was identified. By incorporating these losses into thermal calculations, a good agreement was found between measured and calculated temperatures. Mechanical calculations allowed for the recovery of the horse saddle form after actual welding, with a relative difference of less than 10% in angular distortion between calculated and measured values.

Stress relaxation cracking susceptibility evaluation in 347H stainless steel welds

AbstractStress relaxation cracking (SRC) has been reported as a dominant failure mechanism for 347H stainless steel welds at elevated service temperatures, occurring in either the heat-affected zone (HAZ) or fusion zone (FZ). In this study, SRC susceptibility of physically simulated HAZ and cross-welded E347-347H stainless steel welds was studied using a four-step accelerated SRC test with a thermomechanical physical simulator. The stress and temperature range studied represents weld-induced residual stress at 150–600 MPa and post-weld heat treatment temperatures between 800 and 1050 °C. For all temperature conditions, the cross-welded samples failed at a lower critical stress threshold than the simulated HAZ. A finite element model of a 50.8-mm-thick single-V groove weld was used to generate the residual stress maps induced by a 40-pass welding procedure, which in combination with the experimental threshold stress map predicted potential SRC failure locations. Postmortem microstructural evaluations were performed to identify contributing characteristics to SRC. It was found that HAZ samples exhibited a combination of creep void development, secondary cracks with intergranular fracture near grain boundary carbides, and eutectic phases. FZ samples showed brittle fracture with cracks propagating along straight, non-tortuous interdendritic grain boundaries.