激光起爆数值模拟边界精度对计算结果的影响

在设计激光精密火工品的过程中,炸药的温度场无法通过精密物理实验直接测量,数值计算结果成为炸药温度场最全面可信的依据。为了研究不同边界精度对数值计算的影响,采用不同边界处理方法,利用Fortran语言进行数值计算,并将数值解和解析解进行比较。分析结果后发现:边界条件的精度不同,计算结果出现显著差异。边界条件与内部精度一致的数值计算结果与理论解析解几乎重合,而更适合用作激光精密火工品的设计依据。     

基于铀的激光氮化机理研究和数值模拟

针对工件铀的表面激光氮化工艺,考虑铀的固-液相变过程中各物理参数随温度的变化,结合计算流体软件FLUENT中流体体积函数(VOF)模型计算气-液相界面处的降膜解吸传质过程。进行了铀的瞬态激光氮化传热传质耦合数值仿真,仿真分析研究了不同工艺参数下瞬态温度场和流场的分布,同时获得渗氮量在铀表面和深度上的分布。分析结果表明,因激光局部加热引起的表面张力梯度导致的Marangoni对流对铀表面氮化过程中的传热和传质有很大的影响。其中渗氮量在不同工艺参数下的数值结果与试验结果相吻合,验证了数值模型的可行性,为激光氮化的理论分析和工艺指导提供了理论和方法。     

激光选区熔化热输入参数对Inconel 718合金温度场的影响

采用有限元模拟及实验验证相结合的方法,通过模拟随温度变化的粉体层和已凝固合金层的热物理参数转化及激光往复扫描过程等,研究了不同激光扫描速率和功率条件下,制件温度场分布、熔池大小的变化规律。基于激光线能量密度的激光热输入综合参数,总结了Inconel 718合金激光选区熔化过程中熔池大小的预测方法。结果表明,在激光的作用下,温度场等温线分布呈现椭球型,同时椭球型向已凝固合金层偏移。在本次实验参数研究范围内,激光线能量密度与成型过程中熔池大小之间呈线性增长关系。同时,本研究通过激光选区熔化设备制备了不同激光热输入条件下的Inconel 718合金试样,并对熔池大小进行了实验验证,所得实验数据与模型预测结果吻合良好。     

异种钢激光-电弧焊复合焊接数值模拟

目的研究异种钢激光-GMAW复合焊接温度场以及应力场变化。方法运用ANSYS有限元分析软件,以5 mm厚D500钢和A514钢为研究对象,采用均匀分布的柱体热源与椭球热源组合的方法,建立了激光-GMAW焊接热源模型,对异种钢激光电弧复合焊接过程进行了模拟计算,并与实验所得的焊缝形状以及焊后残余应力进行了对比。结果结果表明,异种钢激光电弧复合焊接过程焊接变形以及残余应力实验结果与数值计算结果吻合较好。结论验证了锥体加柱体热源与椭球热源的组合热源模型在异种钢激光-GMAW复合焊接温度场及应力场模拟中的适用性,从而为不同焊接工艺条件下异种钢激光-GMAW复合焊接的焊缝形状和尺寸预测,提供了一种有效的途径。     

圆柱体激光相变硬化三维温度场数值计算

建立了圆柱体工件激光相变硬化过程的三维传热学模型，根据此模型，采用有限差分法对圆柱体工件在激光相变硬化过程中的三维非稳态温度场进行了数值模拟，预测了42CrMo钢圆柱体工件激光相变硬化区的宽度和深度，对42CrMo钢圆柱体工件进行了激光相变硬化实验，并实测了工件激光相变硬化区的宽度和深度，研究结果表明：采用数值计算的方法，可以准确地计算出圆柱体激光相变硬化过程的温度分布及微观组织分布；预测的激光相变硬化区宽度和深度与实验测量结果符合的较好。     

激光功率对钛合金双侧同步焊接温度场的影响

为研究激光功率对TC4钛合金T型结构双激光束双侧同步焊接温度场的影响,针对TC4钛合金T型结构的双激光束双侧同步焊接过程,建立了相应的有限元模型,利用有限元分析软件进行了焊接过程温度场的计算,研究了激光功率对熔池形状的影响规律,并对不同激光功率下的温度场进行了分析.结果表明:随着激光功率的增加,熔池的熔深、熔宽均有所增...     

基于Fluent的钛合金激光氮化机理及数值模拟

基于非等温产生的表面张力梯度导致熔池区域内的马兰戈尼对流对激光氮化传热和传质过程有重大的影响。本文采用计算流体软件Fluent对钛的激光氮化过程进行探究和重现,结合传热过程中材料温升引起的相变模型及流体体积函数(VOF)模型分析气—液降膜传质机理,通过建立瞬态激光氮化温度场和浓度场的耦合模型,对激光氮化过程的传热,熔池流动和传质机理进行数值模拟。分析结果给出了钛工件的熔池形成、内部流动、氮化层的氮含量及其分布与激光参数之间的关系,为激光氮化工艺参数优化提供了理论依据。     

不同基板预热温度对激光金属沉积成形过程温度场的影响

为降低成形过程的热应力,抑制成形过程裂缝的产生,减小成形过程试样和基板的翘曲变形,激光金属沉积成形往往需要进行基板预热,因此研究不同基板预热温度对激光金属沉积成形过程温度场的影响具有非常重要的意义．根据有限元分析中的“单元生死”技术,利用APDL编程建立了基板预热对激光金属沉积成形过程温度场影响的三维多道多层数值模拟模型,详细分析了基板未预热和分别预热到200,300,400,500,600 ℃时对沉积成形过程温度场和温度梯度的影响．通过中国科学院沈阳自动化研究所自行研制的激光金属沉积成形系统和基板预热系统,在与模拟过程相同的参数下,利用镍基合金粉末在基板未预热和分别预热到300,400,500,560 ℃时进行了成形试验,试验结果跟数值模拟结果吻合较好．     

激光剥离Al2O3/GaN中GaN材料温度场的模拟

对激光剥离Al2O3/GaN技术,建立了紫外脉冲激光辐照过程中GaN外延层内热传导理论模型。计算分析了不同能量密度脉冲激光辐照时,GaN外延层内的温度场分布,由此得到激光剥离的阈值条件。采用紫外KrF准分子激光器对Al2O3/GaN样品进行激光剥离实验,样品表面显微镜和端面扫描电镜(SEM)测试照片说明,计算结果与实验现象相符。进一步分析表明,脉冲激光的能量密度和频率是实现激光剥离的关键参数,适当选取这些参数能将GaN材料内的高温区控制在100nm以内,实现高效低损伤激光剥离。     

激光熔凝过程中三维温度场的数值模拟

采用有限元法,模拟计算了激光表面熔凝单晶合金材料中的三维温度场分布,得到了材料表面及截面的温度梯度分布,为激光熔凝过程中CET转变及液固相变过程中温度梯度G的变化提供了理论依据。将材料热物性参数随温度的变化引入计算模型,并得到了其对计算结果的影响,为下一步残余应力的数值模拟做了预研准备。计算结果表明:随温度变化的材料的热物性参数对温度梯度G的影响较大;在单晶合金凝固过程中,材料内温度梯度G对CET转变起关键作用;模拟结果与实验测量结果吻合很好。     

选择性激光烧结峰值温度的三维有限元模拟

选择性激光烧结(SLS)中工艺参数和扫描路径对烧结件性能有较大影响,文中研究了激光烧结工艺参数和扫描路径对峰值温度的影响规律。通过建立SLS的温度场模型并开发C++的有限元模拟软件,分析了激光功率、激光扫描速率及预热温度等工艺参数对SLS峰值温度的影响,对比了不同扫描路径下高分子粉末和金属粉末的SLS峰值温度变化规律。数值算例表明,SLS温度场中峰值温度随激光功率和预热温度的升高而升高,随激光扫描速率的升高而降低;扫描路径对高分子粉末SLS峰值温度的影响较小;开发的温度场模型准确合理,能够为实际生产提供理论依据。     

激光增材制造热-力耦合数值模拟研究现状及进展

激光增材制造技术加工过程中温度变化迅速而剧烈,导致成形件内部产生复杂的热应力和残余应力,这是成形件发生应力变形、翘曲、开裂等加工缺陷的根本原因。并且,剧烈的温度变化使得难以直接使用实验观察其温度场和应力场演变规律。因此,通过建立有限元模型进行数值模拟的方法来分析热-力耦合场的分布以及其对成形件质量的影响尤为必要。总结了金属激光增材制造技术温度场和应力场的数值模拟研究进展及现阶段存在的一些问题,进一步探讨了金属激光增材制造技术在数值模拟方面的未来发展方向。     

Modeling of a diffusion process in intensive pressure-assisted electrosintering of powder mixtures to a metal base

A computer model is proposed for the diffusion process that occurs in the contact zone between a composite powder and a metal base during intensive pressure-assisted electrosintering of the powder onto the base. The model consists of two parts: (i) a model of the temperature field in the powder sample volumes under study, and (ii) a model of the diffusion process in the contact zone between the powder particles and the metal base during the sintering. The data on the time variation of the contact temperature, as calculated in the first part, are then used in the second one for solving the diffusion problem. The model adequacy has been verified by comparing the calculated data and the results of laboratory investigations of the diffusion between a titanium powder sample and a copper plate during the pressure-assisted sintering. The model proposed can be used to study structural alterations in powder composites being bonded to a metal base by intensive pressure-assisted electrosintering as well as to optimize the sintering process variables for powder composites.     

40Cr轴面激光熔覆Ni60数值模拟

目的 针对激光熔覆过程中熔池内部复杂的传热和对流现象,分析激光功率和扫描速度对熔池内部温度场、流场演变和分布的影响.方法 采用双椭球热源模型,建立了40Cr轴面基体激光熔覆Ni60粉末过程的三维温度场流场数值模型,并进行试验验证.结果 熔覆过程形成了近似椭球体的熔池,最高温度位于移动光斑中心偏后方,达到了2080.4 ...     

金属粉末选择性激光烧结成形机制的研究

分析了纯金属粉末、预合金粉末和多组分金属粉末的选择性激光烧结成形机制;详细讨论了粉末的化学成分和物理性质,激光功率、扫描速率、扫描矢径、扫描间距等激光参数以及粉层厚度、粉床预热温度、保护气氛等工艺参数对成形机制的影响;并简要讨论了金属粉末选择性激光烧结技术的进一步研究方向.     

Computer modeling of temperature field in sintering carbide composites using induction and radiation heating

A computer model has been elaborated for the temperature field in a high-temperature furnace for sintering ceramic powder samples under induction and radiation heating conditions. For numerical solution of the set of equations describing the induction and radiation heating processes a finite-element method is used in combination with a finite-difference procedure in time, which is based on Newton-Raphson technique, and a radiosity method is used in modeling the radiation heat transfer. The temperature field in the furnace in the process of sintering has been numerically studied. The numerical results are compared to the data of temperature measurements at the infiltrator surface during the sintering of a composite blend with a silicon-carbide matrix. Based on the agreement between the calculated and experimental results, the computer model is inferred to be adequate.     

铝电解用NiFe2O4基金属陶瓷的制备

以铝电解惰性阳极为应用目标，制备了不同金属相(Cu—Ni)含量的Ni-Cu／NiFe2O4金属陶瓷，研究了烧结气氛、温度和保温时间对其性能的影响，解决了烧结过程中氧化物陶瓷的离解和金属相被氧化的问题，比较了不同烧结条件下所得试样的基本物理参数，找到了较优的Ni—Cu／NiFe2O4金属陶瓷制备工艺。结果表明：Cu／NiFe2O4金属陶瓷的金属相中添加15wt％ Ni后，可以提高金属相的液相线温度，改善金属相对NiFe2O4陶瓷相的润湿性能，从而可在保证金属相不溢出且分布均匀的前提下，大大提高金属陶瓷的烧结温度和保温时间，显著提高金属陶瓷的致密度，进而改善金属陶瓷惰性阳极的耐腐蚀性能和导电性能。     

金属激光3D打印过程数值模拟应用及研究现状

数值模拟可以高效、有针对性地对金属激光选区熔化成型过程中的温度场、熔池形状、残余应力和变形、凝固过程微观组织演变等过程建立相应的模型并对成形件的相关性能做出准确预测,为工艺优化提供科学的依据,显著降低工艺开发成本和缩短工艺开发周期,有力推动金属增材制造向工业级应用的转变。本文综述了金属激光增材制造过程中温度场、熔池动力学、成形件内部残余应力和变形、显微组织变化4个方面数值模拟的最新研究进展,概述了金属SLM过程数值模拟所取得的最新进展,分析了金属SLM数值模拟领域的研究热点和所存在的计算时间长、成本高等问题,最后提出金属SLM过程数值模拟应将3D打印过程中快速凝固、微熔池等特征与大数据、人工智能、深度学习等技术相结合,进一步提高数值模拟精度,拓宽金属激光增材制造加工窗口,为个性化产品开发提供指导。     

Microstructure evolution of Al-Si-10Mg in direct metal laser sintering using phase-field modeling

Direct metal laser sintering (DMLS) has evolved as a popular technique in additive manufacturing, which produces metallic parts layer-by-layer by the application of laser power. DMLS is a rapid manufacturing process, and the properties of the build material depend on the sintering mechanism as well as the microstructure of the build material. Thus, the prediction of part microstructures during the process may be a key factor for process optimization. In addition, the process parameters play a crucial role in the microstructure evolution, and need to be controlled effectively. In this study, the microstructure evolution of Al-Si-10Mg alloy in DMLS process is studied with the help of the phase field modeling. A MATLAB code is used to solve the phase field equations, where the simulation parameters include temperature gradient, laser power and scan speed. From the simulation result, it is found that the temperature gradient plays a significant role in the evolution of microstructure with different process parameters. In a single-seed simulation, the growth of the dendritic structure increases with the increase in the temperature gradient. When considering multiple seeds, the increasing in temperature gradients leads to the formation of finer dendrites; however, with increasing time, the dendrites join and grain growth are seen to be controlled at the interface. The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0213-1     

A multi-field coupled FEM model for one-step-forming process of spark plasma sintering considering local densification of powder material

A mechanical constitutive model of powder material is introduced to a fully coupled thermal–electric–mechanical finite element model to simulate the one-step-forming spark plasma sintering (SPS) process of metal powders. The effects of displacement field and local density distribution on sintering are considered in this article, which are generally neglected in the existing SPS models. The mechanical, thermal, and electrical parameters of powders are assumed as functions of local relative density and temperature. The simulated varying displacement field remodels the distributions of temperature and electric potential by changing the contact thermoelectric resistances. For the 20, 40, and 60 MPa external pressures, the simulation indicates that the sintering temperature and the temperature gradient within powders are decreased by enhancing the external pressure, and the comprehensive effect of stress promotes the densification of the colder regions. Thus, the interrelationship between the temperature gradient and the intrinsic stress distribution plays an important role in the densification mechanism of SPS powders.