Process model for strength of age hardenable aluminium alloy welds

Abstract

An existing process model for hardness prediction in age hardenable aluminium alloy welds is presented and analysed. One of the key criticisms of this model is that its derivation assumes softening is due to precipitate dissolution alone. The influence of precipitate coarsening has been determined by developing an equivalent model for softening owing to coarsening. It is shown that the experimentally derived master curves that form the basis of the model are capable of representing softening by a mixture of precipitate coarsening and dissolution. Methods to predict post-weld natural aging are discussed, and a new method is presented based on direct prediction of the Guinier–Preston zone fraction. The model has been applied to friction stir welding. Model predictions agree well with measured hardness profiles, and the sensitivity of the predictions to temperature is discussed.     

Optimal configuration of blast furnace slag runner to reduce fluid flow stresses at wall using mathematical modelling

Abstract

A three-dimensional mathematical model was developed to predict the wall shear stresses due to flow of liquid slag in slag runner of 'G' blast furnace of Tata Steel under different conditions. The liquid slag flow in the slag runner was considered to be turbulent and incompressible. The model was developed for single phase, steady state and isothermal conditions. To this end, the Navier Stokes equations along with continuity and turbulence equations (standard k–? model) were simultaneously solved with appropriate boundary conditions at the associated physical boundaries of the calculation domain. Several configurations were numerically assessed with respect to reduced shear stresses on the wall of the slag runner to select the best one. Due to accelerating flow the operating heights of liquid slag (density 2800 kg m^–3 at 1500°C) within the slag runner for different configurations were estimated with the help of Bernoulli's and continuity equations and fixed before the computation. The different configurations comprised of three segments with different parameters of either elevation or radius of curvature. Relatively high shear stresses were numerically predicted at the joint area of second and third segments of the slag runner for all the configurations. The radius of curvature was found as the dominant factor to reduce the shear stress at the joint region.     

Classical thermodynamic approach to void nucleation in irradiated materials

Abstract

One of the major problems in building a future fusion power station is the development of suitable structural materials. These materials will be exposed to high energy neutron bombardment, with consequent changes in their mechanical properties – embrittlement, hardening and swelling, for example. A missing link in modelling these effects is an effective treatment of the nucleation of voids under irradiation. These voids are initially stabilised by transmutation helium but, once formed, grow by vacancy accumulation. In this paper, a quasi-chemical model is developed to calculate the entropy of a steel/helium system. Although a substantial contribution from quasi-chemical effects might be expected, the steady state concentrations of dissolved helium are found to be too low for such effects to manifest. The steady state concentration of dissolved helium is low in absolute terms, but the resulting supersaturation is very high, making it reasonable to assume that all available nucleation sites are instantaneously activated.     

Optimum model for predicting temperature settings on hot dip galvanising line

Abstract

Controlling the annealing cycle in a hot dip galvanising line (HDGL) is vital if each coil treated is to be properly galvanised and the steel is to have the right properties. Current HDGL furnace control models usually take into account the dimensions of the coil to be dipped and, in some cases, the type of steel. This paper presents a new model for monitoring furnace temperature settings, which considers not just the coil dimensions but also the chemical composition of the steel. This enables the model to be adjusted more suitably to each type of steel to be dipped, so that the HDGL annealing cycle is optimised and rendered more efficient in dealing with new products. The ultimate aim is to find a model that is equally efficient for new types of steel coil that have not been processed before and whose dimensions and chemical compositions are different from coils processed previously. To find the best model, this paper compares various new and classical algorithms for developing a precise and efficient prediction model capable of determining the three temperature settings for heating on an HDGL located in Avilés (Spain) on the basis of the physical and chemical characteristics of the coils to be processed and the preset process conditions.     

Wave propagation in fibre reinforced composite plate with circular hole under impact loading

Abstract

In this paper, experimental and numerical methods have been applied to the study of composite dynamics. Dynamic orthotropic photoelasticity is employed in the experimental work and the time domain boundary element method for anisotropic media is adopted for the numerical analysis. A fibre reinforced birefringent composite plate is used to model the semi-infinite orthotropic domain with a circular hole. A rifle bullet was used to exert the impact loading with the loading direction parallel and perpendicular to the fibre direction. In the experiments, the propagation, reflection, and diffraction of the stress wave around the hole were recorded and the results were analysed. The time histories of the stress components were obtained from the same experiments and compared with the results from the corresponding computations carried out using the time domain boundary element method. Some valuable data regarding composite dynamics and associated engineering implications were obtained. The comparative study also demonstrates the applicability and accuracy of the two methods for wave propagation problems in orthotropic media.     

Control of weld composition when welding high strength aluminium alloy using the tandem process

Abstract

A new cost effective process for generating different weld element compositions has been examined. Utilising tandem welding technology, different series aluminium filler wires were mixed in a single weld pool with the result that the composition of the principal alloy elements, copper and magnesium were accurately controlled. Thermodynamic modelling was then used to predict an optimum weld bead composition for eliminating solidification cracking when welding Al2024. In order to validate the predicted target composition, the tandem process was used to control the composition of the weld bead. The presented results show that using this system to deposit a controlled ternary composition weld, solidification cracking was eliminated when welding highly constrained test pieces. In contrast, cracking was evident when using commercially available binary filler wires under the same conditions.     

Thermal ageing and lifetime prediction for organic matrix composites

Abstract

During their thermal ageing in air, organic matrix composites undergo a superficial oxidation leading to a 'spontaneous' cracking. The aim of this article is to present a new strategy of investigation intended to minimise empirism in the field of lifetime prediction. It is based on a kinetic model starting from a radical chain mechanism, initiated by hydroperoxide decomposition, and coupling the oxygen diffusion and consumption kinetics. The model gives access to the thickness distributions of all the chemical changes happening during the exposure. All its parameters have a physical sense and are checkable experimentally. In addition, they obey Arrhenius law, which is not the case for the usual global properties. Some significant results showing the model efficiency are reported. Then, it is shown how, in the near future, the model will be usable to predict changes in mechanical properties.     

CFD modelling of friction stir welding of thick plate 7449 aluminium alloy

Abstract

CFD modelling of friction stir welding has been conducted to understand and optimise the welding of thick, 7449 aluminium alloy for aerospace applications. The aim is to produce high strength, defect free welds that do not break the tool. The models compared different pin profiles and rotation speeds and were undertaken in two stages. The first stage involved creating a thermal model to better understand the generation and flow of heat. The second stage involved analysing the flow near the tool with a two-dimensional model. The traversing force results from the two-dimensional planar models compared favourably with experimental findings. The pressure distribution and deformation region size were compared for the different models. Novel maps of the deformation conditions experienced in each weld were produced. The analysis suggested reasons why some pin profiles and rotation speeds are preferable to others and explained the difference in the traversing force measurements.     

Effect of boundary conditions and heat source distribution on temperature distribution in friction stir welding

Abstract

Welding experiments on Al-6005A have been carried out using a fully instrumented milling machine. The power input was calculated from the measured torque and forces. The thermal cycles were measured at various locations close to the weld centreline. A finite element pseudo-steady-state uncoupled thermal model was developed, taking into account the influence of the welding parameters on the power input. The distribution of the total power input between surface and volume heat sources was also studied. The measured and predicted thermal cycles are in good agreement when proper contact conditions between the workpiece and the backing plate are introduced.