Cracked elastic substrate strip with functionally graded coating under thermal-mechanical loading

This paper investigates the functionally graded coating bonded to an elastic strip with a crack under thermal- mechanical loading. Considering some new boundary conditions, it is assumed that the temperature drop across the crack surface is the result of the thermal conductivity index which controls heat conduction through the crack region. By the Fourier transforms, the thermal-elastic mixed boundary value problems are reduced to a system of singular integral equations which can be approximately solved by applying the Chebyshev polynomials. The numerical computation methods for the temperature, the displacement field and the thermal stress intensity factors （TSIFs） are presented. The normal temperature distributions （NTD） with different parameters along the crack surface are analyzed by numerical examples. The influence of the crack position and the thermal-elastic non- homogeneous parameters on the TSIFs of modes I and 11 at the crack tip is presented. Results show that the variation of the thickness of the graded coating has a significant effect on the temperature jump across the crack surfaces when keeping the thickness of the substrate constant, and the thickness of functionally graded material （FGM） coating has a significant effect on the crack in the substrate. The results can be expected to be used for the purpose of gaining better understanding of the thermal-mechanical behavior of graded coatings.

Thermal-mechanical properties of short carbon fiber reinforced geopolymer matrix composites subjected to thermal load

Short carbon fiber preform reinforced geopolymer composites containing different contents of α-Al2O3 filler （Cr（a-Al2O3）/geopolymer composites） were fabricated, and the effects of heat treatment temperatures up to 1 200 ℃ on the thermal-mechanical properties were studied. The results show that the thermal shrinkage in the direction perpendicular to the lamination of the composites gradually increases with the increase of the heat treatment temperatures from room temperature （25 ℃ ） to 1000 ℃. However, the composites in the direction parallel to the lamination show an expansion behavior. Beyond 1 000℃, in the two directions the composites exhibit a larger degree of shrinkage due to the densification and crystallization. The mechanical properties of the composites show the minimum values in the temperature range from 600 to 800 ℃ as the hydration water of geopolymer matrix is lost. The addition of α-Al2O3 particle filler into the composites clearly increases the onset crystalline temperature of leucite （KAlSi2O6） from the amorphous geopolymer matrix. In addition, the addition of α-Al2O3 particles into the composites can not only help to keep volume stable at high temperatures but also effectively improve the mechanical properties of the composites subjected to thermal load to a certain extent. The main toughening mechanisms of the composites subjected to thermal load are attributed to fiber pulling-out.

Fatigue behaviour of coke drum materials under thermal-mechanical cyclic loading

Coke drums are vertical pressure vessels used in the delayed coking process in petroleum refineries. Significant temperature variation during the delayed coking process causes damage in cracking. There were some studies on coke drums in the form of bulging and the fatigue life estimation for the coke drums, but most of them were based on strain-fatigue life curves at constant temperatures, which do not consider simultaneous cyclic temperature and mechanical loading conditions. In this study, a fatigue testing system is successfully devel- oped to allow performing thermal-mechanical fatigue （TMF） test similar to the coke drum loading condition. Two commonly used base and one clad materials of coke drums are then experimentally investigated. In addition, a comparative study between isothermal and TMF lives of these materials is conducted. The experimental findings lead to better understanding of the damage mechanisms occurring in coke drums and more accurate prediction of fatigue life of coke drum materials.

Thermal-Mechanical Fatigue Behavior and Life Analysis of Cast Ni-base Superalloy K417

In-phase (IP) and out-of-phase (OP) thermal-mechanical fatigue (TMF) behavior of cast Ni-base superalloy K417 was studied. All experiments were carried out under total strain control with temperature cycling between 400-850℃. Both in-phase and out-of-phase TMF specimens exhibited cyclic hardening followed by cyclic softening at the minimum temperature. Besides, they cyclically hardened in the early stage of life followed by cyclic softening at the maximum temperature. OP TMF life was longer than that of IP TMF. Various damage mechanisms operating in different controlled strain ranges and phasing were discussed. A few life prediction methods for isothermal fatigue were used to handle TMF fatigue and their applicability to superalloy K417 was evaluated. The SEM analysis of the fracture surface showed that transgranular fracture was the principal cracking mode for both IP and OP TMF. Oxidation was the main damage mechanism in causing shorter fatigue life for IP TMF compared with OP TMF.

Numerical simulation of a sheet metal extrusion process by using thermal-mechanical coupling EAS FEM

The thermal-mechanical coupling finite element method(FEM)was usedto simulate a non-isothermal sheet metal extrusion process. On thebasis of the finite plasticity consistent with multiplicativedecomposition of the deformation gradient, the enhanced as- sumedstrain(EAS)FEM was applied to carry out the numerical simulation. Inorder to make the computation reliable ad avoid hour- glass mode inthe EAS element under large compressive strains, an alterative formof the original enhanced deformation gradient was employed. Inaddition, reduced factors were used in the computation of the elementlocal internal parameters and the enhanced part of elementalstiffness.

EFFECTS OF STRAIN RATIO ON THERMAL-MECHANICAL CYCLIC STRESS-STRAIN RESPONSE AND FATIGUE LIFE IN DS SUPERALLOY DZ125

The effects of strain ratio on thermal-mechanical cyclic stress-strain response and fatigue life in DS superalloy DZ125 have been studied by performing tests at various strain ratio experiments, under strain-controlled and temperature cycling from 550 to 1000℃. It is shown that thermal-mechanical cyclic stress-strain response behavior not only depend on magnitude of strain, and temperature-loading phase angle, but also strain ratio. Fatigue life at strain ratio Rε=-0.3 is longer than that of strain ratio Rε=-1.0, under in-phase thermal-mechanical loading. However, Fatigue life at strain ratio Rε=-0.3 is shorter than that of strain ratio Rε=-1.0, under out-of-phase thermal-mechanical loading. The thermal-mechanical fatigue (TMF) damage model was discussed. Results of fractography show that fatigue, creep and oxidation damage always occur during TMF. The main damage mode depends on loading wave, strain ratio and magnitude of strain.

First Cycle Effect of Polycrystalline CuZnAl Shape Memory Alloy during Thermal-Mechanical Cycling

The thermal-mechanical (T-M) cycles at constant strain of a polycrystalline CuZnAl alloy have been studied in the. present work. In-situ optical microscopic observations have been made to reveal the features of the phase transitions during T-M cycling. The variation of stress-temperature (S-T) curves and electrical resistance-temperature (R-T) curves accompanying with T-M cycling have been measured by tensile test and electrical resistance measurements. It has been found that the polycrystalline CuZnAl alloy shows apparent morphology changes and properties variations in the first cycle during T-M cycling which is called the first cycle effect in the present work. The stable transformation procedure in the T-M cycle is: martensiteparent phase +residual acicular martensite. This residual martensite possesses the character of stress-induced martensite.

Thermal-Mechanical Efect and Removal Mechanism of Ti-6Al-4V During Laser-Assisted Grinding

The low density and high corrosion resistance of titanium alloy make it a material with various applications in the aerospace industry. However, because of its high specifc strength and poor thermal conductivity, there are problems such as high cutting force, poor surface integrity, and high cutting temperature during conventional machining. As an advanced processing method with high efciency and low damage, laser-assisted machining can improve the machinability of titanium alloy. In this study, a picosecond pulse laser-assisted scratching (PPLAS) method considering both the temperature-dependent material properties and ultrashort pulse laser’s characteristics is frst proposed. Then, the efects of laser power, scratching depth, and scratching speed on the distribution of stress and temperature feld are investigated by simulation. Next, PPLAS experiments are conducted to verify the correctness of the simulation and reveal the removal behavior at various combinations of laser power and scratching depths. Finally, combined with simulated and experimental results, the removal mechanism under the two machining methods is illustrated. Compared with conventional scratching (CS), the tangential grinding force is reduced by more than 60% and the material removal degree is up to 0.948 during PPLAS, while the material removal is still primarily in the form of plastic removal. Grinding debris in CS takes the form of stacked fakes with a “fsh scale” surface, whereas it takes the form of broken serrations in PPLAS. This research can provide important guidance for titanium alloy grinding with high surface quality and low surface damage.

ANALYSIS OF SHAKEDOWN OF FG BREE PLATE SUBJECTED TO COUPLED THERMAL-MECHANICAL LOADINGS

The static and kinematic shakedown of a functionally graded （FG） Bree plate is analyzed. The plate is subjected to coupled constant mechanical load and cyclically varying temperature. The material is assumed linearly elastic and nonlinear isotropic hardening with elastic modulus,yield strength and the thermal expansion coeffcient varying exponentially through the thickness of the plate. The boundaries between the shakedown area and the areas of elasticity,incremental collapse and reversed plasticity are determined,respectively. The shakedown of the counterpart made of homogeneous material with average material properties is also analyzed. The comparison between the results obtained in the two cases exhibits distinct qualitative and quantitative difference,indicating the importance of shakedown analysis for FG structures. Since FG structures are usually used in the cases where severe coupled cyclic thermal and mechanical loadings are applied,the approach developed and the results obtained are significant for the analysis and design of such kind of structures.

Analysis of thermal-mechanical coupled characteristics of vehicle twin-tube shock absorber

A comprehensive model that included mechanical dynamics of the shock absorber coupled with its thermal properties was proposed innovatively.Moreover a thermal-mechanical coupled model which reflected the closed-loop positive feedback system was established by using MATLAB/SIMULINK,and some curves of shock absorber temperature rising characteristic were obtained by simulation ＆computation under several operating modes and different parameters conditions.Research results show that：shock absorber design parameters,external excitations,and thermo-physical properties parameter,such as oil density have effect on the shock absorber temperature rising characteristic.However other thermo-physical properties parameters,such as oil specific heat,cylinder density,cylinder specific heat,and cylinder thermal conductivity,have no effect on it.The results may be used for studying reliability design of the shock absorber.

Thermal-Mechanical Coupled FE Analysis for Rotary Shaft Seals

The aim of this paper is to model the steady-state condition of a rotary shaft seal (RSS) system. For this, an iterative thermal-mechanical algorithm was developed based on incremental finite element analyzes. The behavior of the seal’s rubber material was taken into account by a large-strain viscoelastic, so called generalized Maxwell model, based on Dynamic Mechanical Thermal Analyses (DMTA) and tensile measurements. The pre-loaded garter spring was modelled with a bilinear material model and the shaft was assumed to be linear elastic. The density, coefficient of thermal expansion and the thermal conductance of the materials were taken into consideration during simulation. The friction between the rotary shaft seal and the shaft was simplified and modelled as a constant parameter. The iterative algorithm was evaluated at two different times, right after assembly and 1 h after assembly, so that rubber material’s stress relaxation effects are also incorporated. The results show good correlation with the literature data, which state that the permissible temperature for NBR70 (nitrile butadiene rubber) material contacting with ~80 mm shaft diameter, rotating at 2600/min is 100°C. The results show 107°C and 104°C for the two iterations. The effect of friction induced temperature, changes the width of the contact area between the seal and the shaft, and significantly reduces the contact pressure.

Microstructural evolution and its influence on mechanical and corrosion behaviors in a high-Al/Zn containing duplex Mg-Li alloy after friction stir processing

Ultralight Mg-Li alloys offer promising applications across various fields.Mg-Li alloys enriched with Al and Zn hold theoretical potential for achieving excellent mechanical strength and corrosion resistance.However,the structural and performance characteristics of such Mg-Li alloys,particularly after thermo-mechanical processing,remain inadequately explored and understood.This study investigated the mi-crostructural evolution of a Mg-9Li-5Al-4Zn alloy after friction stir processing and its consequent effects on the mechanical and corrosion performance.The grain size of the alloy was effectively refined and sta-bilized during friction stir processing at various heat inputs.The yield strength of the alloy increased by 86.4%after friction stir processing under the highest heat input condition,which was attributed to fine grain strengthening,solid solution strengthening and dispersion strengthening.Concurrently,the alloy ex-perienced a slight decrease in elongation after the friction stir processing.The alloy subjected to friction stir processing with the highest heat input exhibited a minimal corrosion current density of 6.10×10^(−6) A/cm^(2),which was only 25%of the base metal.The enhanced anti-corrosion properties can be attributed to the dispersion and distribution of precipitated particles induced by friction stir processing,which hin-dered the micro-galvanic corrosion and promoted the generation of a compact surface film,leading to minimal and uniform corrosion.This investigation can be significant for understanding the metallurgical mechanisms and performance evolution of Mg-Li alloys during thermomechanical processes.

Effect of thermo-mechanical treatment on microstructure and mechanical properties of wire-arc additively manufactured Al-Cu alloy

Wire-arc additive manufacture(WAAM)has great potential for manufacturing of Al-Cu components.However,inferior mechanical properties of WAAM deposited material restrict its industrial application.Inter-layer cold rolling and thermo-mechanical heat treatment(T8)with pre-stretching deformation between solution and aging treatment were adopted in this study.Their effects on hardness,mechanical properties and microstructure were analyzed and compared to the conventional heat treatment(T6).The results show that cold rolling increases the hardness and strengths,which further increase with T8 treatment.The ultimate tensile strength(UTS)of 513 MPa and yield stress(YS)of 413 MPa can be obtained in the inter-layer cold-rolled sample with T8 treatment,which is much higher than that in the as-deposited samples.The cold-rolled samples show higher elongation than that of as-deposited ones due to significant elimination of porosity in cold rolling;while both the T6 and T8 treatments decrease the elongation.The cold rolling and pre-stretching deformation both contribute to the formation of dense and dispersive precipitatedθ′phases,which inhibits the dislocation movement and enhances the strengths;as a result,T8 treatment shows better strengthening effect than the T6 treatment.The strengthening mechanism was analyzed and it was mainly related to work hardening and precipitation strengthening.

An Innovative Finite Element Geometric Modeling of Single-Layer Multi-Bead WAAMed Part

Finite element (FE) coupled thermal-mechanical analysis is widely used to predict the deformation and residualstress of wire arc additive manufacturing (WAAM) parts. In this study, an innovative single-layermulti-bead profilegeometric modeling method through the isosceles trapezoid function is proposed to build the FE model of theWAAMprocess. Firstly, a straight-line model for overlapping beads based on the parabola function was establishedto calculate the optimal center distance. Then, the isosceles trapezoid-based profile was employed to replace theparabola profiles of the parabola-based overlapping model to establish an innovative isosceles trapezoid-basedmulti-bead overlapping geometric model. The rationality of the isosceles trapezoid-based overlapping model wasconfirmed by comparing the geometric deviation and the heat dissipation performance index of the two overlappingmodels. In addition, the FE-coupled thermal-mechanical analysis, as well as a comparative experiment of thesingle-layer eight-bead deposition process show that the simulation results of the above two models agree with theexperimental results. At the same time, the proposed isosceles trapezoid-based overlappingmodels are all straightlineprofiles, which can be divided into high-quality FE elements. It can improve the modeling efficiency andshorten the simulation calculation time. The innovative modeling method proposed in this study can provide anefficient and high-precision geometricmodelingmethod forWAAMpart FE coupled thermal-mechanical analysis.

Dynamic explicit FE modeling of hot ring rolling process

A new FE modeling method of hot ring rolling was presented by solving key technologies such as contact and heat boundary conditions,motion control over guide rolls,and mass scaling.The method has the following features:1)the elastic-plastic dynamic explicit approach instead of the static implicit approach is adopted to solve the process so as to greatly improve computational efficiency without sacrificing computational accuracy;2)the coupled thermal-mechanical effect is considered as opposed to the conventional isothermal assumption,which is more practical;3)in contrast to the simplified 2D or local 3D ring model,the full 3D ring is modeled to simulate the process.Based on the FE modeling method,two cases of hot plain ring rolling are simulated in the FEA software ABAQUS/Explicit.The simulation results are compared with the experimental measurements and the good agreement between them is observed regarding the material flow and the temperature distribution of the ring.

Thermal-mechanical coupled effect on fracture mechanism and plastic characteristics of sandstone

Scanning electronic microscopy (SEM) was employed to investigate fractographs of sandstone in mine roof strata under thermal-mechanical coupled effect. Based on the evolution of sandstone surface morphology in the failure process and frac- tography, the fracture mechanism was studied and classified under meso and mi- cro scales, respectively. The differences between fractographs under different tem- peratures were examined in detail. Under high temperature, fatigue fracture and plastic deformation occurred in the fracture surface. Therefore, the temperature was manifested by these phenomena to influence strongly on micro failure mechanism of sandstone. In addition, the failure mechanism would transit from brittle failure mechanism at low temperature to coupled brittle-ductile failure mechanism at high temperature. The variation of sandstone strength under differ- ent temperature can be attributed to the occurrence of plastic deformation, fatigue fracture, and microcracking. The fatigue striations in the fracture surfaces under high temperature may be interpreted as micro fold. And the coupled effect of tem- perature and tensile stress may be another formation mechanism of micro fold in geology.

GURTIN-TYPE VARIATIONAL PRINCIPLES FOR DYNAMICS OF A NON-LOCAL THERMAL EQUILIBRIUM SATURATED POROUS MEDIUM

Based on the porous media theory and by taking into account the efects of the pore fuid viscidity, energy exchanges due to the additional thermal conduction and convection between solid and fuid phases, a mathematical model for the dynamic-thermo-hydro-mechanical coupling of a non-local thermal equilibrium fuid-saturated porous medium, in which the two constituents are assumed to be incompressible and immiscible, is established under the assumption of small de- formation of the solid phase, small velocity of the fuid phase and small temperature changes of the two constituents. The mathematical model of a local thermal equilibrium fuid-saturated porous medium can be obtained directly from the above one. Several Gurtin-type variational principles, especially Hu-Washizu type variational principles, for the initial boundary value problems of dy- namic and quasi-static responses are presented. It should be pointed out that these variational principles can be degenerated easily into the case of isothermal incompressible fuid-saturated elastic porous media, which have been discussed previously.

Microcrack-and microvoid-related impact damage and ignition responses for HMX-based polymer-bonded explosives at high temperature

Investigating the damage and ignition behaviors of polymer-bonded explosive(PBX) under a coupled impact and high-temperature loading condition is required for the safe use of charged PBXs. An improved combined microcrack and microvoid model(CMM) was developed for better describing the thermal effects of deformation, damage, and ignition responses of PBXs. The main features of the model under typical dynamic loadings(i.e. uniaxial tension and compression, and lateral confinement) at different initial temperature were first studied. And then the effects of temperature on impact-shear sensitivity of HMX-based PBXs were investigated. The results showed that the ignition threshold velocity of shear-crack hotspots exhibits an increase from 260 to 270 to 315-325 m/s when initial temperature increases from 301 to 348 K;and then the threshold velocity decreases to 290-300 m/s with the initial temperature continually increasing to 378 K. The predicted ignition threshold velocity level of the explosives under coupled impact and high temperature loading conditions were consistent with the experimental data.

Investigation of meso-failure behavior of rock under thermal-mechanical coupled effects based on high temperature SEM

It is extremely important to study and understand the deformation behavior and strength characteristics of rocks under thermal-mechanical （TM） coupling effects. Failure behavior and strength characteristics of Pingdingshan sandstone were investigated at room temperatures up to 300℃ in an internally heated apparatus and tensile load through meso-scale laboratory experiments in this work. 33 experiments have successfully been conducted for Pingdingshan sandstone. Experimental results indicated that the tensile strength increased slowly with temperatures from 25℃ to 100℃, and then sharply jumped from 100℃ to 150℃, and finally decreased slightly with temperatures from 150℃ to 300℃. And about 150℃ is the threshold temperature of strength and thermal cracking. At low temperatures （25℃-150℃）, sandstone strength is determined by relatively weak clay cement. However, at higher temperatures （150℃-300℃）, because of the strength enhancement of clay cement, sandstone strength is controlled by both mineral particles and clay cement. The effects of cement clay, micro-cracks closing, and thermal cracking were the possible reasons for our detailed analysis. In addition, the typical fracture position maps and nominal stress-strain curves indicated that the temperature had strong effects on the failure mechanism of sandstone. The fractograph implied that the dominant fracture mechanism tended to transform from brittle at low temperatures to ductile at high temperatures.

BREAKAGE MECHANISM OF TUNGSTEN BASED ALLOY BLOCK FOR ELECTRO-HEAT UPSETTING

The breakage mechanism of W-Ni-Fe alloy in the process of electro-heat upsetting studied both theoretically and experimetnally, and also the behaviors of crack formation and propagation were analysed. Alloy suffers from corrosion and thermal-mechanical fatigue mutual function. Simultaneously, the practical ways to improve the anvil life was discussed.