Transient Thermal Stress Research Articles

Prediction of transient thermal stress distribution in SOFC based on coupled computational fluid dynamics and thermodynamics modeling

Long-term stability and safety are two key factors for the application of solid oxide fuel cell (SOFC) technology, with thermodynamics playing a central role in influencing this stability. Thus, understanding the thermodynamic behavior within SOFC and how it will depend on the stack structure are very important, especially at the start and stop stages. In this study, a 3D calculated fluid dynamics model and thermomechanical coupling model based on the actual component structures are established. We place emphasis on understanding how these factors evolve during dynamic phases, shedding light on the transient thermal stress behavior of the SOFC. The influence of different interconnect structures on the thermal stress distribution is studied. The coupling calculation results show that the first principal stress of the electrolyte is significantly affected by the specific interconnect structure. Adopting cylindrical ribs instead of rectangular ribs, the thermal stresses of the SOFC components can be reduced by 13–25 %, respectively.

Size-dependent transient thermal stress analysis of a rotating thin and moderately thick porous FGM microblade under cooling thermal shock

Size-dependent transient thermal stress analysis of a rotating thin and moderately thick porous FGM microblade under cooling thermal shock

Numerical simulation of transient thermal stresses in medium- and high-temperature latent heat storage systems with different fins: Incorporation of experimental stress cracking

Latent heat storage systems play an essential role in energy applications by improving the utilization efficiency and increasing the system flexibility. In this study, a pilot-scale medium-to-high-temperature latent heat storage system was constructed, and experimental heat storage tests were conducted. The temperature distribution of the experimental system was verified through numerical simulations that coupled the physical fields of the fluids, heat transfer, and solid mechanics. Also, the changing dynamic behavior of the stresses in the heat storage process related to the experiments was carefully studied. It was discovered that there were stress concentrations where the heat exchanger tubes touched the casing, with the highest level being over 370.00 MPa. Experimental stress rupture of the shell occurred in the horizontally arranged heat-exchange tubes, whereas vertically arranged tubes significantly reduced the stress at the contact surfaces by 24.70 % according to simulations. Simulation studies on various influencing factors indicated a more significant impact of spiral fins on the system stress. Increasing the preheating temperature by 30 °C reduced stress on the front surface by 109.67 MPa; each 20 °C increase in heating temperature raised the stress by 223.30 MPa, whereas the effect of heat transfer fluid speed was minimal. Regarding the heat-exchange tube dimensions, increasing the height increased the tube body stress by 25.74 MPa, whereas increasing the thickness reduced the stress by 24.20 %. This study comprehensively analyzed the stress dynamics and mitigation strategies of the high-temperature latent heat storage system under various conditions, emphasizing the importance of heat-exchange tube orientation, temperature control, and fin design for optimizing system performance and durability.

Thermodynamic behavior and microstructure evolution of Inconel 718 alloy by laser metal deposition

The temperature evolution, stress evolution, and dendrite growth during the laser metal deposition (LMD) process of Inconel 718 alloy were simulated using a multi-scale model that combines the finite element method and the Cellular Automata (CA) method. This model established the relationship between the thermal behavior of the molten pool and the solidification characteristics, and predicted the morphological size of the solidified structure. Research indicates that under conditions of higher cooling rate and lower shape control factor, equiaxed grains are prone to form, with a lower degree of elemental segregation in this region, which is conducive to the precipitation of granular Laves phase. Conversely, under conditions of lower cooling rate and higher shape control factor, columnar grains are more likely to form, with a higher degree of elemental segregation in this region, leading to the precipitation of chain-like Laves phase. The results of thermo-mechanical coupled simulation suggest that the maximum transient thermal stress is located at the overlap position, and when the component cools down to room temperature, the maximum normal stress along the scanning direction is observed. Dendritic growth results demonstrate that during the equiaxed grain growth process in the top region of the melt pool, the released solute is constrained by time and space, leading to the accumulation of solute and the formation of interdendritic segregation. In areas with a higher grain density, the solute accumulation zones overlap, resulting in an increase in solute concentration, which inhibits dendrite growth. In the middle region of the melt pool, during the columnar grain growth process, the solute concentration in the gaps between adjacent grains continuously increases, resulting in micro-segregation phenomena. Experimental measurements have shown that the temperature field's melt pool morphology, stress values along the scanning path, and dendritic morphology are in good agreement with the experimental outcomes.

A finite volume–based thermo-fluid-mechanical model of the LPBF process

The multi-physics coupling feature of the laser powder bed fusion (LPBF) process poses great challenges to numerical models regarding computational fidelity and efficiency. This paper proposed a finite volume–based model for predicting integrated thermo-fluid-mechanical behaviors of the LPBF process. The model directly unifies the heat transfer, fluid flow and solid mechanics simulations within a predefined mesh, enabling simultaneous solutions for the fluid domain under Eulerian description and the solid domain under Lagrangian description. Three benchmark tests accounting for individual problems were conducted to validate the model's accuracy and effectiveness. Track-scale LPBF simulations were performed to unravel the intricate interplay between thermal, fluid and mechanical behaviors. The numerical predictions of surface morphologies, molten pool dynamics and melt track dimensions aligned well with the experimental observations. The spatiotemporal evolution of transient thermal stress was accurately captured and the predicted residual stress field showed consistency with nanoindentation measurements. The proposed model was found robust in simultaneously predicting the temperature distribution, melt flow and residual stress evolutions of the LPBF process, and showed strong potential for addressing other similar multi-physics coupling problems.

Optimal design of laminated thermoelectric cylindrical device based on neural network and thermo-electric-mechanical coupled model

The laminated thermoelectric cylindrical shell is favorable for solar thermal energy harvesting, but the thermo-electric-mechanical coupling field is relatively complex. An optimization design model of thermoelectric structure is required to promote its practical application. In this paper, based on variable separation method, thermo-electric-mechanical coupled model of laminated thermoelectric cylindrical device under thermal shock is constructed. Transient temperature field, thermal stress and power generation efficiency are obtained. Numerical results show that both power generation efficiency and thermal stress are affected by material parameters simultaneously. In order to analyze efficiency and structural reliability comprehensively, a fitness function is introduced in this paper. Based on the data which are collected from thermoelectric coupled model, a neural network is established and trained, which can predict and evaluate the performance of thermoelectric cylindrical shell based on the fitness function. The optimal material parameters for thermoelectric shells with high efficiency and low thermal stress are obtained. Combining neural network technique and the theoretical model developed in this paper, the computation time of numerical results can be reduced from 50 to 3 min, and this neural network optimization method has higher computational efficiency. These research results will provide guidance for the optimization design of cylindrical thermoelectric device.

Assessment of transient thermal stresses in gasketed plate heat exchangers

Thermal and mechanical stresses in stainless steel 316 L plates of gasketed plate heat exchangers (GPHEs) have been assessed with the aid of experiments. Stresses were indirectly determined with the aid of extensometers in critical plate areas. To the best of our knowledge, no experimental analysis of transient thermal loads on GPHE plates has been reported before. Experiments occurred with sudden and gradual heating processes with the aid of strain gauges. The former process implies that hot fluid enters the GPHE branch with the final target temperature, while the latter indicates that the hot fluid is progressively heated to the target temperature. Furthermore, combined mechanical and thermal stresses resulting from in-phase and out-of-phase loads are assessed in single and double operating conditions. Experiments were carried out with two plate thicknesses (0.5 and 0.7 mm). Stresses as obtained from experiments were compared to those provided by models containing simplified geometries and boundary conditions. Mechanical stresses promoted by the pressure difference between GPHE branches mostly affected the distribution area in single configuration. Thermal stresses at the porthole were higher than the ones found at the distribution zones, particularly for thicker plates. Besides, thermal stresses increased in double operation. Sudden heating processes with the system at rest promoted thermal peaking stress in a timescale of seconds, while the timescale to reach peak values by gradually heating the hot fluid is in the order of minutes. The most critical condition would be achieved at the porthole with in-phase loads and in double operation for the given settings.

Investigation of two collinear cracks in fiber reinforced composites under thermal loading

The objective of this paper is to explore the transient behaviors of fiber reinforced composites with two embedded collinear cracks subject to a sudden thermal shock. The orthotropic composites with both the vertically oriented and horizontally aligned fibers are examined to present a systematic comparison. By means of the integral transform methodology and singular integral equations, the thermal and elastic governing equations are solved numerically to determine the transient thermal process and stress intensifications around the crack tips. Parametric investigations are carried out for fiber volume fractions and crack distances. The findings would be beneficial to a more thorough knowledge of fibrous composites’ fracture characteristics under thermal shocks, which helps material design and structural optimization of the composites with fiber reinforcements.

Functionally graded bi-material interface for Porcelain Veneered Zirconia dental crowns: A study using viscoelastic finite element analysis

ObjectivesDuring the manufacturing of Porcelain Veneered Zirconia (PVZ) dental crowns, the veneer-core system undergoes high-temperature firing cycles and gets fused together which is then, under a controlled setting, cooled down to room temperature. During this cooling process, the mismatch in thermal properties between zirconia and porcelain leads to the development of transient and residual thermal stresses within the crown. These thermal stresses are inherent to the PVZ dental crown systems and render the crown structure weak, acting as a precursor to veneer chipping, fracture, and delamination. In this study, the introduction of an intermediate functionally graded material (FGM) layer at the bi-material interface is investigated as a potentially viable alternative for providing a smoother transition of properties between zirconia and porcelain in a PVZ crown system. MethodsAnatomically correct 3D crown models were developed for this study, with and without the FGM layer modeled at the bi-material interface. A viscoelastic finite element model was developed and validated for an anatomically correct bilayer PVZ crown system which was then used for predicting residual and transient stresses in the bilayer PVZ crown. Subsequently, the viscoelastic finite element model was further extended for the analysis of graded sublayers within the FGM layer, and this extended model was used for predicting the residual and transient stresses in the functionally graded PVZ crown, with an FGM layer at the bi-material interface. ResultsThe study showed that the introduction of an FGM layer at the bi-material interface has the potential to reduce the effects from transient and residual stresses within the PVZ crown system relative to a bilayer PVZ crown structure. Furthermore, the study revealed that the FGM layer causes stress redistribution to alleviate the stress concentration at the interfacial surface between porcelain and zirconia which can potentially enhance the durability of the PVZ crowns towards interfacial debonding or fracture. SignificanceThus, the use of an FGM layer at the bi-material interface shows a good prospect for enhancing the longevity of the PVZ dental crown restorations by alleviating the abrupt thermal property difference and relaxing thermal stresses.

Mechanical properties and thermal shock resistance of TiB2‒B4C composite ceramic tool materials at microscopic scale

AbstractA finite model incorporating microstructure was developed to investigate the thermal shock resistance of TiB2‒B4C composite ceramic cutting tool materials. Numerical simulations were conducted to analyze changes in the transient temperature field and thermal stress field during the thermal shock process. TiB2‒B4C composite ceramic tool materials were fabricated using discharge plasma sintering technology. With different B4C contents, different sintering temperatures and holding times as study variables, optimization of the sintering process parameters and ceramic material components was achieved through testing the mechanical and microscopic morphology of the ceramics. Thermal shock water quenching experiments were performed, and the strength‐decay method was employed to assess the thermal shock resistance of TiB2‒B4C ceramics. The findings indicate that the optimal sintering conditions are temperature of 1700°C and holding time of 5 min. The TiB2‒B4C ceramic material containing 20 vol% B4C exhibits superior comprehensive mechanical properties and thermal shock resistance, and its relative density, fracture toughness, hardness, and flexural strength were 99.3%, 6.8 MPa m1/2, 22.8 GPa, and 598 MPa, respectively. The critical thermal shock temperature difference falls within the range of 400°C‒500°C.

Thermal fatigue failure analysis and life assessment of Ni-based single crystal superalloys with film cooling holes

The transient thermal fatigue behavior of Ni-based single crystal superalloys with film cooling holes under different peak temperatures (25 °C → 980 °C and 25 °C → 1050 °C) were investigated by a combination of test and finite element simulation. The initiation position and propagation direction of thermal fatigue cracks in both single hole and multi-hole specimens exhibit the angles of ± 45° with respect to the horizontal direction at the four corners of the holes. Octahedral slip failure mainly occurred at the crack initiation location and crack tip. The cyclic oxidation around the film cooling hole promotes the initiation and propagation of cracks. Based on the crystallographic theory, the strain–stress constitutive equation of the Ni-based single crystal superalloy under transient thermal shock was established. The location and evolution of thermal stress around the hole at different temperatures were obtained by finite element calculation. The kinetic behavior of cyclic oxidation has been quantitatively characterized. A thermal fatigue crack initiation life model considering heating temperature, transient thermal stress, and cyclic oxidation has been established. The simulation results are in good agreement with the tests.

Optimisation of material composition in functionally graded plates for thermal stress relaxation using statistical design support system

Abstract This study addresses the optimisation of material composition in a functionally graded plate for thermal stress relaxation, subjected to through-thickness thermal gradients, with the aim of minimising a stress utilisation ratio. We simplify the problem by approximating the functionally graded plate as a multi-layered plate. Material compositions in individual layers are optimised using a statistical design support system (SDSS), incorporating design of experiments and mathematical programming techniques. The volume fractions of ceramic constituent in the respective layers are considered as design variables, and an analytical solution for transient thermal stresses is utilised to evaluate the objective function. The optimisation results obtained using the SDSS are compared with those from a genetic algorithm (GA) to validate the applicability of the proposed method. Our findings indicate that the SDSS replicates the ceramic volume fraction distribution optimised by the GA, while significantly reducing optimisation time.

Numerical study of transient supercooling performance and thermal stress analysis of segmented annular thermoelectric cooler

A multiphysics-coupled numerical simulation of a segmental annular thermoelectric cooler (SATEC) was performed using a three-dimensional finite element method. A coupling model of the temperature, stress, and electric fields was established based on the three-dimensional transient states. Moreover, the effects of different pulse width (τ), pulse current amplitude (Pa), pulse current shape parameter (m), heat transfer coefficient (h), angle (θ), and length (H) of the thermoelectric leg on the SATEC transient properties and von Mises stress were studied. The results show that τ and Pa are the key influencing factors of SATEC. The larger the h, the more optimized the heat transfer effect of the SATEC hot end. However, when h increased to a certain value, the changes in the transient performance were insignificant. The optimal pulse can be achieved when the input pulse current Iop = 6.47 A and pulse width τ = 20 s. When the length of the thermoelectric leg H4 was 3 mm and the thermoelectric leg angle θ2 was 7°, the performance of SATEC was optimal, with Tc,min being 249.57 K, Tc,max being 279.50 K, thold being 5.5 s, and the maximum von Mises stress being 37.48 MPa. The results show that different supercooling indices and von Mises stresses could be obtained for different pulse current shapes. Geometric optimization of SATEC can improve the cooling performance and reduce the von Mises stress, thereby providing a theoretical reference for practical engineering applications and thermoelectric cooling research.

Numerical study of transient temperature thermal stress coupled heat transfer in spent fuel storage cask based on Gaussian random heat source

Spent fuel storage is a necessary part of the entire lifecycle to achieve intrinsic safety in the application of nuclear energy as a clean energy source, and should be adequately investigated. Based on a Gaussian stochastic heat source, this paper presents a three-dimensional coupled numerical model of the heat-stress multiphysics field for the dry storage cask. Comparison with the literature model is carried out to verify that the error is less than 10%, and the temperature field and stress field distribution law of the storage cask under different initial temperatures of the spent fuel rods are studied and discussed. The raise of the initial temperature enhances the heat transfer and the change of the temperature gradient across the shell is the main cause of the stress change. This study provides a reference for the subsequent design study of spent fuel storage casks.

Optimal control of thermal and mechanical loads in activation processes of mechanical components

This paper develops a mathematical framework that aims to control the temperature and rotational speed in the activation process of a gas turbine in an optimal way. These controls influence the deformation and the stress in the component due to centripetal loads and transient thermal stress. An optimal control problem is formulated as the minimization of maximal von Mises stress over a given time and over the whole component. To find a solution for this, we need to solve the linear thermoelasticity and the heat equations using the finite element method. The results for the optimal control as functions of the rotation speed and external gas temperature over time are computed by sequential quadratic programming, where gradients are computed using finite differences. The overall outcome reveals a significant reduction of approximately 10%, from 830 N mm 2 to 750 N mm 2 , in von Mises stress by controlling two parameters, along with the temporal separation of physical control phenomena.

Transient thermal stress analysis of a thin rotating FGM blade based on the exact shear correction factor: a comparison of ROM and LRVE homogenization models

This work is an attempt to develop a simple and accurate finite element formulation based on first-order shear deformation theory (FSDT) for the transient thermal stress analysis of a pre-twisted and tapered thin rotating functionally graded material (FGM) blade, induced due to the thermal shock. The neutral surface of the FGM blade is taken as the reference plane and the exact shear correction factor is obtained from the equivalent energy principle. The temperature-dependent material property at a point in the thickness direction is estimated according to the rule of mixture (ROM) and the Local representative volume elements (LRVE) homogenization model. A finite element formulation using FSDT in conjunction with the eight-noded isoparametric element, taking five degrees of freedom is developed. The top layer of the thin FGM blade is subjected to a thermal shock and the bottom layer is kept at the ambient temperature. The governing equation for the present formulation is obtained using Hamilton’s principle. The accuracy of the present finite element formulation is established by comparing the results with the benchmark results. The parametric studies are conducted to investigate the effect of the angle of twist, variable chord and span, rotational speed, and accurate shear correction factor on the transient thermal stresses due to the thermal shock. Notably, there can be significant differences in the transient thermal stresses calculated by the two homogenization models viz., ROM and LRVE. Also, it is important to consider the exact shear correction factor in the formulation.

Thermal shock fracture in a cracked strip: Incorporating convective heat transfer between lateral surfaces and ambient environment

This paper presents a comprehensive analysis of transient temperature and thermal stress around a thermal insulated crack in a finite thermoelastic strip subjected to thermal shock based on the dual-phase-lag (DPL) heat conduction. A detailed investigation of the effect of convective heat exchange between the lateral surfaces of the strip and the ambient environment is conducted. By employing integral transform technique, the thermoelastic crack problem is reduced to a set of singular integral equations, and solutions for the transient temperature distribution and dynamic stress intensity factors (SIFs) at the crack tips are then obtained. Numerical results reveal a considerable temperature gradient near the heating surface when both the high convective heat transfer coefficient and thin strip are involved. Consequently, the SIFs in such scenarios where cracks are located close to the heating surface are significantly larger compared to those calculated by neglecting the convective heat loss. Furthermore, during the initial period following a thermal shock, the SIFs may exhibit higher magnitudes than the steady-state values. These findings emphasize the importance of accounting for the influence of convective heat exchange with the ambient environment in material design and optimization to enhance fracture resistance under transient thermal loading.

Multilayer gradient rare earth disilicate coating prepared by in-situ melt infiltration and sintering method with high thermal shock resistance on porous Si3N4 ceramics

Dense multilayer gradient rare earth disilicate (γ-Y2Si2O7 /β-Yb2Si2O7 /β-Lu2Si2O7) coatings were in-situ prepared by melt-infiltration /sintering procedure on porous Si3N4 ceramics for water resistance. Experimental and numerical simulation methods were used to study their thermal shock behavior. As a control, thermal shock behavior of pure γ-Y2Si2O7 coatings were also compared. FEM results showed that the gradient design of modulus in ceramic coating can effectively avoid the mismatch of mechanical properties between coating layer and internal substrate, reducing the transient thermal stress in each layer during thermal shock. All of the pure γ-Y2Si2O7 coatings were failed after thermal shock tests with ΔT ≈ 1200 ℃. However, when sintering temperature of multi-layer disilicate coatings were higher than 1400 ℃, the water absorption rates after thermal shock were all less than 5%, still showing good waterproof performance. The gradient design of modulus could effectively improve the structural stability of ceramic coatings.

Design and performance evaluation of a multi-disc magnetorheological fluid brake for A00-class minicars

This paper presents the design and performance evaluation of a multi-disc magnetorheological fluid (MRF)-based brake (MRB) for A00-class minicars. The braking performance of the MRB is studied by means of theoretical analysis and experimental verification. Firstly, the MRB is designed according to the shear model of the MRF, and the structure optimization is carried subsequently. Secondly, multi-physical simulations of the MRB are conducted to investigate the transient temperature field, thermal stress and thermal strain distribution of the MRB under different braking models; Finally, a performance evaluating testbed is built to experimentally assess the braking performance of the MRB. The results indicate that the theoretical braking torque of the MRB fulfills the target value. The thermal strain-induced deformation of the disc is minimal and has a negligible effect on the torque output. In addition, the MRB is experimentally validated to exhibit excellent braking performance in terms of sufficient torque output capacity, rapid response, low temperature rise characteristic, as well as favorable velocity following property.

Operando neutron diffraction reveals mechanisms for controlled strain evolution in 3D printing

Residual stresses affect the performance and reliability of most manufactured goods and are prevalent in casting, welding, and additive manufacturing (AM, 3D printing). Residual stresses are associated with plastic strain gradients accrued due to transient thermal stress. Complex thermal conditions in AM produce similarly complex residual stress patterns. However, measuring real-time effects of processing on stress evolution is not possible with conventional techniques. Here we use operando neutron diffraction to characterize transient phase transformations and lattice strain evolution during AM of a low-temperature transformation steel. Combining diffraction, infrared and simulation data reveals that elastic and plastic strain distributions are controlled by motion of the face-centered cubic and body-centered cubic phase boundary. Our results provide a new pathway to design residual stress states and property distributions within additively manufactured components. These findings will enable control of residual stress distributions for advantages such as improved fatigue life or resistance to stress-corrosion cracking.