Analytical modelling of residual stress in additive manufacturing

A physics‐based analytical model to assess residual stresses in additive manufacturing made of metallic materials is presented and validated experimentally. The model takes into consideration the typical multi‐pass aspect of additive manufacturing. First, the thermal signature of the process is assessed by predicting the temperature for the problem of a moving heat source, then, the thermally induced stresses in a homogenous semi‐infinite medium are determined. Taking the thermal stresses as input, the residual stresses are calculated analytically to obtain the distribution across the depth. Good agreement is obtained between the analytical prediction and X‐ray measurements made on Selective Laser Melted 316L Stainless Steel. In addition, the analytical approach enables in‐depth interpretations of results with basis in the true mechanisms of the process. Thus, the present model appears as a promising tool for optimization of process parameters in additive manufacturing, which in turn will improve the understanding of process parameters and their effect on properties of the final product.     

Continuum structural topological optimizations with stress constraints based on an active constraint technique

Stress‐related problems have not been given the same attention as the minimum compliance topological optimization problem in the literature. Continuum structural topological optimization with stress constraints is of wide engineering application prospect, in which there still are many problems to solve, such as the stress concentration, an equivalent approximate optimization model and etc. A new and effective topological optimization method of continuum structures with the stress constraints and the objective function being the structural volume has been presented in this paper. To solve the stress concentration issue, an approximate stress gradient evaluation for any element is introduced, and a total aggregation normalized stress gradient constraint is constructed for the optimized structure under the r?th load case. To obtain stable convergent series solutions and enhance the control on the stress level, two p‐norm global stress constraint functions with different indexes are adopted, and some weighting p‐norm global stress constraint functions are introduced for any load case. And an equivalent topological optimization model with reduced stress constraints is constructed,being incorporated with the rational approximation for material properties, an active constraint technique, a trust region scheme, and an effective local stress approach like the qp approach to resolve the stress singularity phenomenon. Hence, a set of stress quadratic explicit approximations are constructed, based on stress sensitivities and the method of moving asymptotes. A set of algorithm for the one level optimization problem with artificial variables and many possible non‐active design variables is proposed by adopting an inequality constrained nonlinear programming method with simple trust regions, based on the primal‐dual theory, in which the non‐smooth expressions of the design variable solutions are reformulated as smoothing functions of the Lagrange multipliers by using a novel smoothing function. Finally, a two‐level optimization design scheme with active constraint technique, i.e. varied constraint limits, is proposed to deal with the aggregation constraints that always are of loose constraint (non active constraint) features in the conventional structural optimization method. A novel structural topological optimization method with stress constraints and its algorithm are formed, and examples are provided to demonstrate that the proposed method is feasible and very effective. © 2016 The Authors. International Journal for Numerical Methods in Engineering published by John Wiley & Sons Ltd.     

Irregular Time‐Varying Stress Degradation Path Modeling: a Case Study on Lithium‐ion Cell Degradation

The aim of this paper is to investigate the issue of degradation modeling and reliability assessment for products under irregular time‐varying stresses. Conventional degradation models have been extensively used in the relevant literature to characterize degradation processes under deterministic stresses. However, the time‐varying stress, which may affect degradation processes, widely exists in field conditions. This paper extends the general degradation‐path model by considering the effects of time‐varying stresses. The new degradation‐path model captures influences of varying stresses on performance characteristics. A nonlinear least square method is used to estimate the unknown parameters of the proposed model. A bootstrap algorithm is adopted for computing the confidence intervals of the mean time to failure and percentiles of the failure‐time distribution. Finally, a case study of lithium‐ion cells is presented to validate the proposed method. Copyright © 2015 John Wiley & Sons, Ltd.     

纤维缠绕复合材料起伏区域残余应力

针对纤维交叉起伏区域残余应力,建立一种细观分析模型。基于热传导方程、固化反应动力学模型和复合材料层合理论,采用有限元方法和细观分析模型,对缠绕复合材料在固化工艺过程中的残余应力分布及其变化规律进行数值模拟。通过算例,研究纤维起伏区域残余应力的分布特点,结果表明:起伏纤维束不同位置处残余应力差别很大,层合区纤维束呈现拉应力状态,起伏区纤维束呈现压应力状态,富树脂区出现最大压应力;残余应力沿纤维束起伏方向呈现V型变化趋势,在纤维束上不同位置出现拉、压不同的应力状态,起伏角度最大处出现最大压应力。     

pH值对7050铝合金膜致应力和应力腐蚀敏感性的影响

采用慢应变速率拉伸法和流变应力差值法研究了7050铝合金在3.5%(质量分数)NaCl水溶液中膜致应力和应力腐蚀敏感性随pH值的变化规律。结果表明:当pH≤7时,随着pH值的增大,膜致应力和应力腐蚀敏感性均下降,当pH7时,膜致应力和应力腐蚀敏感性随着pH值的增大而提高;而当pH=1,14时,腐蚀的类型为剥蚀,合金基体发生剥落,表面没有钝化膜产生。pH值在6~9之间时,膜致应力随pH的变化比较平缓,而pH在2~5和10~13之间时,膜致应力变化则较为剧烈,整体的变化曲线呈山谷形。膜致应力和应力腐蚀敏感性具有很强的相关性。XPS研究表明,膜致应力值与钝化膜的成分有关。     

快速电沉积法制备镍基金刚石复合镀层EI北大核心CSCD

为解决镍基金刚石复合电沉积过程中普遍存在镀层沉积速率慢、镀层内应力大的问题,本工作以新型高速Ni镀液为基础,考查了镀液中去应力添加剂含量、工艺参数,以及金刚石含量对镀层内应力影响的规律,并对复合镀层的微观形貌进行了表征。优选出了可以在30A/dm2的高阴极电流密度下快速电沉积低应力镍基金刚石复合镀层的镀液组成及工艺条件。结果表明：当镀液组成为十二烷基硫酸钠0.5g/L,乙酸铵3g/L,柠檬酸三钠1.5g/L,金刚石微粒浓度30g/L;施镀条件为pH值3~4,温度50℃时,制得的复合镀层内应力最低。     

等效球药包迭加模型的应力计算分析

结合Starfield单元球迭加原理,认为单元球药包的质量和个数是影响条形药包近场应力特征的主要因素。在分析条形药包的现有理论研究方法的基础上,引入条形药包的长径比参数,构建了单孔装药量的爆破应力迭加公式。通过具体的算例得出:当条形药包的装药直径取4 cm时,计算出的最优长径比范围为10~12,装药量(TNT)为544~654 g。通过迭加公式的理论模型与其数值模型的应力场分布特征进行对比分析,发现迭加球药包应力场在径向方向始终呈柱面波形式向外扩散,并同时存在"端部效应";其理论值和模拟值的相对误差控制在20%以内,验证了应力迭加公式的计算方法是可行的,为单孔装药引起的应力计算和应力场分析提供了一个简易的数学模型。