Determination of surface heat-transfer coefficients of steel cylinder with phase transformation during gas quenching with high pressures

In numerical simulation of quenching process, the boundary conditions of temperature field and stress field are very important, in which the boundary conditions of temperature field are very complicated. In order to simulate the thermal strains, thermal stresses, residual stresses and microstructure of the steel during gas quenching by means of the numerical method, it is necessary to obtain an accurate boundary condition of temperature field. The surface heat-transfer coefficient is a key parameter. The explicit finite difference method, non-linear estimate method and the experimental relation between temperature and time during quenching have been used to solve the inverse problem of heat conduction. The relationships between surface temperature and surface heat-transfer coefficient of cylinder have been given. The non-linear surface heat-transfer coefficients include the coupled effects between phase transformation and temperature. In calculation, physical properties were treated as the function of temperature and volume fraction of constituent. The results obtained have been shown that this technique can determine effectual the surface heat-transfer coefficients during gas quenching.     

Finite element calculation and measurement of thermal stresses in quenched plates of high–strength 7075 aluminium alloy

Abstract

Thick parts of high–strength aluminium alloys usually undergo a drastic quench which gives rise to thermal stresses and may cause distortion of products. The control of complex phenomena involved during quenching is achieved by determining the temperature distribution, thermal strains, and residual stresses using the MARC finite element program. In this approach, the thermo mechanical problem is assumed to be uncoupled, i.e. the thermal and mechanical calculations are solved consecutively. First a non–linear heat transfer analysis is performed taking the temperature dependence of the thermophysical properties and transient conditions of convection at the surface of the plate into account. This is followed by a thermo–elastoplastic stress analysis using the predicted temperature distributions, assuming an isotropic behaviour of the material and taking the temperature dependence of its mechanical properties into account. The calculation of thermal stresses occurring during the cold and hot water quenching of a 70 mm thick plate of 7075 alloy using this method shows a good agreement between theoretical predictions and experimental values of residual stresses, as measured by the layer removal method.

MST/2     

Application of Differential Transform Method to Thermoelastic Problem for Annular Disks of Variable Thickness with Temperature-Dependent Parameters

This article analyzes the one-dimensional steady temperature field and related thermal stresses in an annular disk of variable thickness that has a temperature-dependent heat transfer coefficient and is capable of temperature-dependent internal heat generation. The temperature dependencies of the thermal conductivity, Young’s modulus, and the coefficient of linear thermal expansion of the disk are considered, whereas Poisson’s ratio is assumed to be constant. The differential transform method (DTM) is employed to analyze not only the nonlinear heat conduction but also the resulting thermal stresses. Analytical solutions are developed for the temperature and thermal stresses in the form of simple power series. Numerical calculations are performed for an annular cooling/heating fin of variable thickness. Numerical results show that the sufficiently converged analytical solutions are in good agreement with the solutions obtained by the Adomian decomposition method and give the effects of the temperature-dependent parameters on the temperature and thermal stress profiles in the disk. The DTM is useful as a new analytical method for solving thermoelastic problems for a body with temperature-dependent parameters including material properties.     

W18Cr4V合金工具钢在不同介质淬火后性能比较

通过对W18Cr4V合金工具钢在清水、锭子油和高压气体等淬火介质中淬火对比实验,研究W18Cr4V合金工具钢在不同介质淬火工艺处理后的硬度和微观结构.研究结果表明,水淬火时试件表面与中心的温差较大,锭子油次之,高压气体较小;试件高压气体淬火时,温度剃度小,内部冷却比较均匀,可以预计,相应的热应力和热变形也比较小;应用较小压力的氮气能够实现淬透性比较好的W18Cv4V工具合金钢的高压氮气淬火处理.     

Observations on the characteristics of a fluidized bed for the thermal shock testing of brittle ceramics

The heat transfer characteristics of a fluidized bed used as a quenching medium for the thermal stress testing of brittle ceramics, were determined by measurements of the thermal shock behaviour of rods of a soda-lime—silica glass. The heat transfer coefficient was found to be strongly dependent on the mean particle size of the powder and air flow rate, and was relatively independent of the position within the bed. The results indicate that the heat transfer coefficient during thermal shock fracture may have a value lower than that obtained under heat transfer conditions which more closely resemble steady state. The heat transfer data inferred from the quenching experiments with the glass gave excellent agreement between calculated and measured values for the thermal shock behaviour for rods of a polycrystalline aluminium oxide. It is concluded that fluidized beds are excellent inert quenching media with variable heat transfer coefficient controlled by particle size and flow rate.     

竖直矩形通道内不凝性气体对凝结换热特性的影响

本文以去离子水为工质,实验研究了竖直矩形窄通道内少量残余不凝性气体对蒸汽凝结换热特性的影响。采用热阻分离法得到凝结侧换热表面传热系数,分析了不凝性气体的含量、冷却水质量流速、进口温度和热流密度对蒸汽凝结侧表面传热系数的影响。结果表明:当热流密度为1.668 kW/m~2,即蒸汽质量流速较小时,2%体积分数的不凝性气体使凝结侧表面传热系数下降了33%,但当热流密度为3.887 kW/m~2,蒸汽质量流速较大时,2%体积分数的不凝性气体仅使凝结侧表面传热系数降低了14%,此外,凝结换热表面传热系数随冷水质量流速和不凝性气体分数的增加而变小,随冷水进口温度和热流密度的增加而变大。     

Minimizing Stress and Distortion for Shafts and Discs by Controlled Quenching in a Field of Nozzles

A coupled gas‐dynamical and thermo‐mechanical model for simulation of the gas flow, gas and specimen temperature, phase, stress, strain, and displacement transient‐fields during quenching of cutting discs and shafts of steel is introduced. The material properties (e. g. density, conductivity, heat capacity, hardness) are obtained by homogenization procedures. The material behaviour is described as an extension of the classical J₂‐plasticity theory with the extension of temperature and phase fraction dependent yield criteria. The coupling effects such as dissipation, phase transformation enthalpy, and transformation induced plasticity (TRIP) are considered. Simulations were carried out for cutting discs of knives, and for shafts made of steel SAE 52100 with varying diameter. For the validation of the simulations, these work pieces were heated in a roller hearth kiln up to 850 °C, and than quenched in a field of nozzles in which the heat transfer coefficient was known and could be locally adjusted by the volume flow of each nozzle. The phase fractions, surface hardness, distortion, and residual stresses were measured. The simulated and measured results fit quite well. According to optimization‐simulations the shafts were quenched with a certain heat transfer coefficient distribution. The bigger diameter parts of the shaft were more intensively quenched by an increased gas flow so that the hardness profiles were equalized and the residual stresses at the edges were significantly reduced.     

Berechnung der Temperaturfelder in Bremssystemen

This paper presents an iterative method for the investigation of the quasi-stationary temperature field of frictional hot spot moving on the infinite half-space. The nonlinear differential equation of heat transfer has been transformed to a nonlinear integral equation. It was assumed that the thermal conductivity coefficient and the specific heat strongly depend on the actual temperature. In the case of a graphite half-space the dependence of contact temperature on the contact pressure as well as on the velocity has been presented. The temperature distribution, taking into consideration the thermal sensitivity of physical parameters, has been illustrated perpendicularly to the surface of half-space. The results can allow the thermal analysis of brake systems.     

Numerical method of thermal shock resistance estimation by quenching of samples in water

A temperature dependence of a transient heat transfer for cylindrical and ball samples (of different surface roughness) of 3–60 mm diameters heated up to the temperature range from 150 to 1200° C and quenched in a water bath of large volume was established. The measurement errors of the transient heat transfer defined by different methods with regard to hysteresis and statistical nature of boiling phenomena were evaluated. The study revealed, that the transition point from bubble to film boiling and vice versa differs essentially. The transient heat transfer in the field of bubble boiling did not depend on the size and the shape of the samples, their surface roughness and thermo-physical properties. But the magnitude of hysteresis in changing between the boiling regimes were substantially governed by the geometrical and thermo-physical characteristics of the samples. The examples of thermal stresses estimation which caused quenching damage to ZrC samples, heated up to a wide range of temperature from 150 to 1200 C, are given. The obtained data on the transient heat transfer and proposed recommendation on the temperature regimes of quenching for convenient sample sizes can form a basis of a standard for the numerical evaluation of the thermal shock resistance.     

7A04铝合金构件深冷处理过程瞬态温度场的数值模拟

建立了7A04铝合金构件深冷处理过程瞬态温度场的有限元模型,对7A04铝合金材料在低温状态下的若干物性参数进行了实验研究,并运用温度场反算法分别得到了铝合金试件与低温（热）介质之间的传热系数。运用ABAQUS6．5有限元软件,对7A04铝合金构件瞬态温度场的数值结果表明,在淬火、深冷与上坡淬火过程中,构件上端部位存在很陡峭的温度梯度。     

Effect of Differential Thermal Expansion Coefficient on Stresses Generated in Coating

Two different spraying powders [81FVNS and 80% (443)+20% (105)] were plasma sprayed on two types of substrates (AISI 316 and Ti) in order to verify the effect of differential thermal expansion coefficient (DTEC) between coating and substrate on the final residual stresses generated in the coating. Modulus of elasticity (E) was evaluated for the substrates and coatings (as a composite beam). Free-standing coatings were used to measure the thermal expansion coefficient, as a function of temperature, of the actual coatings with all defects, impurities and typical lamella structure. The results show that the residual stresses seems to be less dependent on the linear thermal expansion coefficients mismatching between substrate and coating, reflecting the importance of the other sources of stresses. i.e. quenching or deposition stresses induced during spraying. The suitable heat treatment condition of the coated samples may release some or most of the residual stresses. However in some cases the sign of the stress was completely changed as a result of neglecting the quenching stresses.     

Residual stresses in plastics,rapidly cooled from the melt,and their relief by sectioning

A theory for the residual stresses in tempered glass plates has been adapted for the cooling of plastics, which have temperature dependent thermal properties. The theory was checked against experimental residual stress distributions found in quenched polycarbonate sheet, and against the analytical solution for temperature independent properties. The heat transfer coefficient for quenching polycarbonate from 170° C into iced water was found to lie between 1000 and 4000 W m^–2 K. It is known that the cutting of thin sections from a sheet relieves the residual stresses, and this is used for transparent plastics to distinguish between orientation and stress bi-refringence. An elastic stress analysis of the sectioning process showed that the section width must be less than 20% of the sheet thickness for the residual stresses to be reduced to 5% of their original values.     

Effect of bath and specimen temperature on the thermal stress resistance of brittle ceramics subjected to thermal quenching

The effect of specimen and bath temperature on the failure of brittle ceramics in a thermal quench experiment was studied by quenching glass and alumina rods in water and silicon oil baths at different temperatures. The results were discussed in terms of the variation of heat transfer coefficient of the quenching media and the change in material properties as a function of temperature. It was found that the usual assumption of constant heat transfer coefficient and material properties may lead to considerable errors in the quantitative interpretation of the results of thermal quench experiments. Effective values for the film coefficient of heat transfer for water and oil baths were estimated as a function of film temperature from thermal quench data. Recommendations were made for the selection of quenching media and for the procedure to be followed in reporting the results.     

Toward a method of thermal shock testing of structural ceramics

Characteristics of the process of development of thermal stresses in a cooled rod with a varying heat transfer coefficient are theoretically studied. It is established that the dependence of stresses on initial temperature of specimen heating is almost linear with a smooth variation in slope in the range of temperatures corresponding to maximum steepness of the right slope of the temperature dependence of the heat transfer coefficient. The importance of standardizing the water temperature within a narrow range to facilitate reproducibility of the thermal loading rigidity is established. It is recommended that specimens be guarded against cooling during their furnace-to-water bath transfer.Translated from Problemy Prochnosti, No. 7, pp. 76–79, July, 1990.     

Experimental study on the convective heat transfer coefficient of early-age concrete

During the process of setting and hardening in concrete, the temperature profile shows a gradual nonlinear distribution due to the development of heat of hydration in cement. At early ages of concrete structures, this nonlinear distribution can have a large influence on crack evolution. It is thus important to obtain an accurate temperature history, and to do this, it is necessary to examine the thermal properties of the concrete. In this study, the convective heat transfer coefficient, which represents the heat transfer between a concrete surface and ambient air, was experimentally investigated with test variables such as the velocity of wind, the curing conditions, and the ambient temperature.For analyses using the thermal equilibrium boundary condition, it is generally noted that most of the heat release by the evaporation of moisture occurs at an early stage. To consider this phenomenon, the existing thermal equilibrium boundary condition has been modified so as to consider the evaporation quantity due to the evaporation effect. Convective heat transfer coefficients for a specific case were then calculated from the modified thermal equilibrium boundary condition using experimental results.     

Transient-temperature and residual-stress fields in axisymmetric metal components after hardening

Abstract

A finite-element method is used to analyse the transient–temperature and residual-stress fields in an axisymmetric metal specimen during quenching. In the calculation of transient-temperature fields it is assumed that an unsteady source of latent heat exists in the specimen when a phase transformation occurs. Factors such as the surface heat transfer coefficient, heat conductivity coefficient, linear expansion coefficient, density, specific heat capacity, latent heat, and so forth are all temperature dependent. The elastic-plastic properties of the specimen are modified according to temperature fields, which are determined; the influence of plastic deformation on the temperature fields is neglected. The agreement between the calculated results and the experimental data shows that the numerical analysis method is reliable. The method may also be applied to the analysis of specimens with other than axisymmetric shape.

MST/15     

Using three-dimensional finite element analysis for simulation of residual stresses in railway wheels

One of the most important issues in railway wheels is residual stresses. It is desirable to produce less residual stresses when possible and to decrease the remaining residual stresses in the wheels. The objective of this paper is to provide an estimation of the residual stresses in the rail wheel caused by the stress field from heat treatment process of a railway wheel. A three-dimensional nonlinear stress analysis model has been applied to estimate stress fields of the railway mono-block wheel in heat treatment process. After forging or casting, railway wheels are heat-treated to induce the desirable circumferential compressive residual stress in the upper rim. Finite element analysis model is presented applying the elastic–plastic finite element analysis for the rail wheel under variable thermal loads. Calculative analysis applying a finite element method (FEM) has been used to predict residual stresses. The quenching and annealing segments of the wheel manufacturing process are simulated using a decoupled heat transfer and stress analysis. Three-dimensional finite element analysis results obtained show good agreement with those achieved in field measurements.     

Thermal conductance of metal interfaces at low temperatures

In the present work the dependence of the heat transfer coefficient between Cu and Sn, Cu and Pb, and Cu and W on the temperature and an external magnetic field has been measured. The preparation of the metal-metal junctions has been performed by melting so that a close contact at the interface was guaranteed. The heat transfer coefficient has been found by a steady-state measuring method. In the case of the Cu-Pb junction the heat transfer coefficient could be measured both in the superconducting and normal states. For all the metal—metal junctions in the normal state a linear temperature dependence of the heat transfer coefficients on the temperature has been found. In the superconducting state a strong reduction of the heat transfer coefficient has been observed. In addition, a theoretical calculation of the heat transfer coefficient on metal-metal interfaces is given. First we consider the scattering of electrons on a steplike potential barrier between two gases of free electrons. Then the thermal conductance due to scattering in an alloy layer is calculated. Such an alloy layer may arise from diffusion during the contact preparation. Comparison of these two cases with the experiments shows the thermal conductance at the interface is mainly determined by the electron scattering on lattice irregularities in the diffusion layer.     

Thermal shock behavior of ZrB2--SiC ceramics with different quenching media

The thermal shock behavior of ZrB₂--SiC ceramics was studied with water, air and methyl silicone oil as quenching media, respectively. The temperature of all coolants was room temperature (25°C) and the residual strength of the ceramics after quenching was tested. The strength of the ceramics after water quenching had an obvious drop when the temperature difference, ΔT, was about 275°C, while the residual strength of the specimens quenched by air and silicone oil only varied a little and even increased slightly when the temperature difference was higher than 800°C. The different thermal conductive coefficient of the coolants and surface heat transfer coefficient resulted in the differences in the thermal shock behavior. The formation of oxidation layer was beneficial for improving the residual strength of the ceramics after quenching.     

Identification of materials in a hyperbolic annular fin for a given temperature requirement

This article deals with the prediction of parameters in an annular hyperbolic fin with temperature-dependent thermal conductivity. Three parameters such as thermal conductivity, variable conductivity coefficient and the surface heat transfer coefficient have been predicted for satisfying a prescribed temperature distribution on the surface of fin. This is achieved by a hybrid differential evolution-nonlinear programming optimization method. The effect of random measurement errors is also considered. It is observed from the present inverse analysis that many feasible materials exist satisfying the given temperature distribution, thereby providing engineering flexibility in selecting any material from the available choices. For a given material, this is possible by regulating the surface heat transfer coefficient.