Finite element analysis on temperature field and residual stress of welding assembly for I-beam and end-plate

Based on full scale model of 1-beam and end-plate welding assembly with medium plate, welding temperature field and residual stress were simulated, infrared thermometers were employed to measure the real-time temperature Jbr verification purposes. Results show that the measured thermal cycle curves match well with the simulation result. Simulation results of welding residual stress indicate that the values of longitudinal and transverse stress on the upper surface of the plate are higher than the normal stress; higher tensile stresses exist at the end of the web weld toes and in the central area of the flange weld toes. The dangerous zones are located at the central areas of weld toes of the flange welds and near weld toes of the web welds.

Calculation of Mass Concrete Temperature and Creep Stress under the Influence of Local Air Heat Transfer

Temperature-induced cracking during the construction of mass concrete is a significant concern.Numerical simulations of concrete temperature have primarily assumed that the concrete is placed in an open environment.The problem of heat transfer between the air and concrete has been simplified to the concrete’s heat dissipation boundary.However,in the case of tubular concrete structures,where air inlet and outlet are relatively limited,the internal air temperature does not dissipate promptly to the external environment as it rises.To accurately simulate the temperature and creep stress in tubular concrete structures with enclosed air spaces during construction,we establish an air–concrete coupled heat transfer model according to the principles of conjugate heat transfer,and the accuracy of the model is verified through experiments.Furthermore,we conduct a case study to analyze the impact of airflow within the ship lock corridor on concrete temperature and creep stress.The results demonstrate that enhancing airflow within the corridor can significantly reduce the maximum concrete temperature.Compared with cases in which airflow within the corridor is neglected,the maximum concrete temperature and maximum tensile stress can be reduced by 12.5℃ and 0.7 MPa,respectively,under a wind speed of 4 m/s.The results of the traditional calculation method are relatively close to those obtained at a wind speed of 1 m/s.However,the temperature reduction process in the traditional method is faster,and the method yields greater tensile stress values for the corridor location.

Evolution of residual stress field in 6N01 aluminum alloy friction stir welding joint

Based on the characteristics of friction stir welding( FSW) and Coulomb friction work theory,the residual stresses field of FSW joints of 6 N01 aluminum alloy( T5),which was used in high speed train,were calculated by using the ANSYS finite element software. During the FEM calculation,the dual heat source models namely the body heat source and surface heat source were used to explore the evolution law of the welding process to the residual stress field. The method of ultrasonic residual stress detecting was used to investigate the residual stresses field of the 6 N01 aluminum alloy FSW joints. The results show that the steady-state temperature of 6 N01 aluminum alloy during FSW is about 550 ℃,and the temperature mutates at the beginning and at end of welding. The longitudinal residual stress σ_x is the main stress,which fluctuates in the range of-25 to 242 MPa. Moreover,the stress in the range of shaft shoulder is tensile stress that the maximum tensile stress is 242 MPa,and the stress in the outside of shaft shoulder is compressive stress that the maximum compressive stress is 25 MPa. The distribution of the tensile stress in the welding nugget zone( WNZ) is obviously bimodal,and the residual stress on the advancing side is higher than that on the retreating side. With the increasing of the welding speed,the maximum temperature decreased and the maximum residual stress decreased when the pin-wheel speed kept constant. With the increasing of the pin-wheel speed,the maximum temperature of the joint increased and the maximum residual stress increased when the welding speed was constant. The experimental results were in good agreement with the finite element results.

Temperature and stress fields in electron beam welded Ti-15-3 alloy to 304 stainless steel joint with copper interlayer sheet

Electron beam welding of Ti-15-3 alloy to 304 stainless steel （STS） using a copper filler metal was carried out. The temperature fields and stress distributions in the Ti/Fe and Ti/Cu/Fe joint during the welding process were numerically simulated and experimentally measured. The results show that the rotated parabola body heat source is fit for the simulation of the electron beam welding. The temperature distribution is asymmetric along the weld center and the temperature in the titanium alloy plate is higher than that in the 304 STS plate. The thermal stress also appears to be in asymmetric distribution. The residual tensile stress mainly exists in the weld at the 304 STS side. The copper filler metal decreases the peak temperature and temperature grade in the joint as well as the residual stress. The longitudinal and lateral residual tensile strengths reduce by 66 MPa and 31 MPa, respectively. From the temperature and residual stress, it is concluded that copper is a good filler metal candidate for the electron beam welding of Ti-15-3 titanium alloy to 304 stainless steel.

Modeling of Temperature and Residual Stress Fields Resulting from Impacting Process of a Molten Ni Particle onto a Flat Substrate

Several effective numerical techniques,based on a finite element analysis,have been developed and computed independently.Results are presented describing the impacting process,and the subsequent temperature and residual stress fields of a molten nickel particle impacting onto a flat substrate.Problems of this type,especially the prediction of the thermal residual stresses,are of major practical interest in thermal spray operations as a pioneering approach.

Numerical Simulation of Temperature Field and Thermal Stress Field of Work Roll During Hot Strip Rolling

Based on the thermal conduction equations, the three-dimensional （3D） temperature field of a work roll was investigated using finite element method （FEM）. The variations in the surface temperature of the work roll during hot strip rolling were described, and the thermal stress field of the work roll was also analyzed. The results showed that the highest roll surface temperature is 593 ℃, and the difference between the minimum and maximum values of thermal stress of the work roll surface is 145.7 MPa. Furthermore, the results of this analysis indicate that temperature and thermal stress are useful parameters for the investigation of roll thermal fatigue and also for improving the quality of strip during rolling.

COUPLED NUMERICAL SIMULATION ON COLD ROLLER'S TEMPERATURE FIFLD-PHASE TRANSFORMATION - STRESS FIELD DURING ITS QUENCHING PSOCESS

Complicated changns occur inside the steel parts during quenching process. The abruptly changed boundary conditions make the temperature field,micro - structure and stress field change dramatically in very short time, and these variables take a contact interactions in the whole process. In this paper, a three dimensional non - linear mathematical model for queeching process has been founded and the numerical simulation on temperature field,microstructre and stress field has been realized.In the FEM analysis, the incremental iteration method is used to deal with such complicated nonlinear as boundary nonlinear, physical property nonlinear,transformation nonlinear etc.The effect of stress on transformation kinetics has been considered in the calculation of microstructure. In the stress field anal- ysis,a thermo- elasto - plastic model has been founded, which considers such factors as transforma- tion strain,transformation plastic strain, themal strain and the effect of temperature and transforma- tion on mechanical propertier etc. The transient temperature field, microstructure distribution and stress field of the roller on any time can be displayed vividly,and the cooling curve and the changes of stress on any position can also be given.

Shakedown Criterion Employing Actual Residual Stress Field and Its Application in Numerical Shakedown Analysis

Construction of the static admissible residual stress field and searching the optimal field are key tasks in the shakedown analysis methods applying the static theorem. These methods always meet dimension obstacles when dealing with complex problems. In this paper, a novel shakedown criterion is proposed employing actual residual stress field based on the static shakedown theorem. The actual residual stress field used here is produced under a specified load path, which is a sequence of proportional loading and unloading from zero to all the vertices of the given load domain. This ensures that the shakedown behavior in the whole load domain can be determined based on the theorem proposed by K6nig. The shakedown criterion is then implemented in numerical shakedown analysis, The actual residual stress fields are calculated by incremental finite element elastic-plastic analysis technique for finite deformation under the specified load path with different load levels. The shakedown behavior and the shakedown limit load are determined according to the proposed criterion. The validation of the criterion is performed by a benchmark shakedown example, which is a square plate with a central hole under biaxial loading. The results are consistent with existing results in the literatures and are validated by full cyclic elastic-plastic finite element analysis. The numerical shakedown analysis applying the proposed criterion avoids processing dimension obstacles and performing full cyclic elastic-plastic analysis under arbitrary load paths which should be accounted for appearing. The effect of material model and geometric changes on shakedown behavior can he considered conveniently.

Nondestructive Testing and Characterization of Residual Stress Field Using an Ultrasonic Method

To address the difficulty in testing and calibrating the stress gradient in the depth direction of mechanical components, a new technology of nondestructive testing and characterization of the residual stress gradient field by ultrasonic method is proposed based on acoustoelasticity theory. By carrying out theoretical analysis, the sensitivity coefficients of different types of ultrasonic are obtained by taking the low carbon steel（12%C） as a research object. By fixing the interval distance between sending and receiving transducers, the mathematical expressions of the change of stress and the variation of time are established. To design one sending-one receiving and oblique incidence ultrasonic detection probes, according to Snell law, the critically refracted longitudinal wave（LCR wave） is excited at a certain depth of the fixed distance of the tested components. Then, the relationship between the depth of LCR wave detection and the center frequency of the probe in Q235 steel is obtained through experimental study. To detect the stress gradient in the depth direction, a stress gradient LCR wave detection model is established, through which the stress gradient formula is derived by the relationship between center frequency and detecting depth. A C-shaped stress specimen of Q235 steel is designed to conduct stress loading tests, and the stress is measured with the five group probes at different center frequencies. The accuracy of ultrasonic testing is verified by X-ray stress analyzer. The stress value of each specific depth is calculated using the stress gradient formula. Accordingly, the ultrasonic characterization of residual stress field is realized. Characterization results show that the stress gradient distribution is consistent with the simulation in ANSYS. The new technology can be widely applied in the detection of the residual stress gradient field caused by mechanical processing, such as welding and shot peening.

Finite element analysis of temperature and stress fields during selective laser melting process of Al−Mg−Sc−Zr alloy

A 3D finite element model was established to investigate the temperature and stress fields during the selective laser melting process of Al−Mg−Sc−Zr alloy.By considering the powder−solid transformation,temperaturedependent thermal properties,latent heat of phase transformations and molten pool convection,the effects of laser power,point distance and hatch spacing on the temperature distribution,molten pool dimensions and residual stress distribution were investigated.Then,the effects of laser power,point distance and hatch spacing on the microstructure,density and hardness of the alloy were studied by the experimental method.The results show that the molten pool size gradually increases as the laser power increases and the point distance and hatch spacing decrease.The residual stress mainly concentrates in the middle of the first scanning track and the beginning and end of each scanning track.Experimental results demonstrate the accuracy of the model.The density of the samples tends to increase and then decrease with increasing laser power and decreasing point distance and hatch spacing.The optimum process parameters are laser power of 325−375 W,point distance of 80−100μm and hatch spacing of 80μm.

Numerical Simulation of Temperature and Stress Fields of Ti-Alloy Thin-well Barrel during Quenching Process

The mathematical models have been established to describe the temperature and stress profiles in T16A14V cylinder during quenching. The residual stress and deformation of the workpiece can be predicted precisely based on ANSYS software. The simulated results show that the temperature of the divided element decreases faster at the edge than that at the internal of the workpiece during quenching from 1050 to 20°C. The largest temperature difference and dimension change in diameter are about 90°C and -0.935%, respectively. The position of largest tensile stress occurs around the edge of the cylinder.

EFFECT OF TENSILE STRESS AND RESIDUAL STRESS ON THE SPONTANEOUS STRAY FIELD SIGNALS FROM THE SURFACE OF 0.45%C STEEL

In order to explore the quantitative method of metal magnetic memory testing（MMMT） and clarify the relationship between Hp（y）, the normal component of spontaneous stray field, and applied stress or residual stress, the static tensile tests of 0.45%C steel sheet specimens are carried out on a servo hydraulic MTS810 machine. Hp（y） values are measured during the test process by an EMS-2003 metal magnetic memory diagnostic apparatus and a non-magnetic electric control displacement instrument. Residual stresses of some points on the surface of a specimen are measured by a Stress Tech X-Stress 3000 X-ray diffraction instrument. The results show that the same variation rules of Hp（y） value versus applied tensile stress are presented under the different conditions of load-on and load-off. However, the same rule does not exist between the Hp（y） value and residual stress. The variation of Hp（y） value reflects the history of applied tensile stress.

Analysis on high-temperature oxidation and growth stress of iron-based alloy using phase field method

High-temperature oxidation is an important property to evaluate thermal protection materials. However, since oxidation is a complex process involving microstructure evolution, its quantitative analysis has always been a challenge. In this work, a phase field method （PFM） based on the thermodynamics theory is developed to simulate the oxidation behavior and oxidation induced growth stress. It involves microstructure evolution and solves the problem of quantitatively computational analysis for the oxidation behavior and growth stress. Employing this method, the diffusion process, oxidation performance, and stress evolution axe predicted for Fe-Cr-A1-Y alloys. The numerical results agree well with the experimental data. The linear relationship between the maximum growth stress and the environment oxygen concentration is found. PFM provides a powerful tool to investigate high-temperature oxidation in complex environments.

SIMULATION OF TEMPERATURE AND THERMAL STRESS FIELD IN LASER MILLING PROCESSING

The physical model of temperature field and thermal stress field are established in this paper, on which the numerical simulation with the assuming physical and laser milling parameters have been finished. The laser milling process can be explained.

Simulation Analysis on Temperature Field and Temperature Stress of Flexible Pavement in Cold Areas

In order to ensure the service life of pavement in cold areas, this paper simulates the temperature field and stress field of pavement at high temperature of 60˚C and low temperature of -30˚C based on ANSYS software, and analyzes the changing trend of temperature of each layer with time and the temperature stress caused by it using the time-incremental finite element method. The results show that when the temperature is higher than 0˚C, the temperature between layers of the structure and the surface temperature shows an increasing trend. On the contrary, when the temperature is lower than 0˚C, it shows a decreasing trend. The more drastic the temperature change is, the greater the temperature stress of the pavement will be, which is easy to cause road structure diseases. When the temperature difference of pavement reaches 90˚C, the change of temperature stress between layers of road structure has a significant effect on the daily evolution of pavement.

Residual stress and welding distortion of Al/steel butt joint by arc-assisted laser welding-brazing

The thermo-elastic.plastic finite element method(FEM)is used to simulate the thermo-mechanical behavior of Al/steel tungsten inert gas(TIG)arc-assisted laser welding-brazing(A-LWB)butt joint.The influence of material nonlinearity,geometrical nonlinearity and work hardening on the welding process is studied,and the differences in the welding temperature field,residual stress and welding distortion by A-LWB and by single laser welding-brazing(SLWB)are analyzed.The results show that the thermal cycle,residual stress distribution and welding distortion by the numerical simulation are in good agreement with the measured data by experiments,which verifies the effectiveness of FEM.Compared with the SLWB,A-LWB can make the high-temperature distribution zone of weld in width direction wider,decrease the transverse tensile stress in the weld and reduce the distribution range of longitudinal tensile stress.And the welding deformation also decreases to some extent.

Stress Field Analysis of Carburized Specimen and Its Numerical Simulation

Residual stress field of carburized specimens was determined experimentally and simulated by using a finite element method (FEM). The experimental results show that the compressive residual stress is formed in carburized layer of the specimen. The peak value of compressive stress appears inside of carburized layer. The calculated results are tallied with the measured ones quite well, which proves the FEM model used for simulation is correct. According to this model, the stress field of carburized specimen during quenching process was also analyzed in this paper.

Stress induced magnetic field abnormality

Residual stresses in ferromagnetic material affect the direction and structure of domains and generate magnetic field abnormality on the surface. In the formation of stress induced magnetic field, the influence of geomagnetic field is unclear. Residual stress specimen was produced by tight matching of a round ring and a peg. The magnetic fields of contrast specimens, which were produced in geomagnetic field or in shielding geomagnetic field, were inspected with 8 mm lift-off. The results show that mean amplitude of magnetic field of the specimen produced in geomagnetic field is 0.85% larger than that of specimen produced in shielding geomagnetic field. So the formation of stress induced magnetic field abnormality above the surface of inspected ferromagnetic material geomagnetic field gives little contribution.

Evaluation of properties and thermal stress field for thermal barrier coatings

In order to get thermal stress field of the hot section with thermal barrier coating (TBCs), the thermal conductivity and elastic modulus of top-coat are the physical key properties. The porosity of top-coat was tested and evaluated under different high temperatures. The relationship between the microstructure (porosity of top-coat) and properties of TBCs were analyzed to predict the thermal properties of ceramic top-coat, such as thermal conductivity and elastic modulus. The temperature and stress field of the vane with TBCs were simulated using two sets of thermal conductivity data and elastic modulus, which are from literatures and this work, respectively. The results show that the temperature and stress distributions change with thermal conductivity and elastic modulus. The differences of maximum temperatures and stress are 6.5% and 8.0%, respectively.

Influence of stress on the stray field signals of ferromagnetic materials

To investigate the influence of stress alone on the stray field signals of ferromagnetic materials,the static tensile tests of 0.45%C steel and 45CrNiMoVA steel flat-shaped specimens were performed on an MTS810 hydraulic testing machine. Hp（y） signals,the normal component of spontaneous stray field,were measured during the testing process by an EMS-2003 metal magnetic memory diagnostic apparatus cooperated with a non-magnetic electric control displacement instrument. Fracture and microstructure were observed by a scanning electronic microscope and a transmission electron microscope,respectively. The relationships between axial applied stress or residual stress measured by X-ray diffraction method and Hp（y） were analyzed. The results indicate that some regular pattern of the magnetic curve is displayed only between applied stress and stray field signals. The magnetic ordering process stops due to dislocation pinning magnetic domain structure,and Hp（y） value unvaried nearly with applied load increasing in the plastic deformation stage.