Numerical and Experimental Study of Plastic Deformation During Flash Butt Welding of X65 Pipeline Steel

2020 ◽  
Vol 142 (4) ◽  
Author(s):  
P. C. Zhao ◽  
Y. T. Hu ◽  
L. L. Wang ◽  
Z. W. Liu
Keyword(s):  
Plastic Deformation ◽  
Liquid Metal ◽  
Metal Film ◽  
Pipeline Steel ◽  
Coupling Model ◽  
Butt Joint ◽  
Contact Interface ◽  
Butt Welding ◽  
Mechanical Coupling ◽  
The Given

Abstract The plastic deformation during flash-butt welding (FBW) and its effects on weld quality are investigated by using numerical and experimental methods. The electro-thermo-mechanical coupling model of FBW is validated by comparing the calculated temperature and plastic deformation to measured one, obtaining reasonable agreement. The calculation results reveal that a thin liquid metal film forms at the contact interface during accelerating flash stage to provide temperature conditions for upsetting. The length of liquid metal (including burning and expelled losses) is 29.7 mm for one piece pipeline tube under the given condition. The stress and strain at contact surface are both almost zero at the initial stage of upsetting due to the thin liquid metal film existing at the contact interface, and they rapidly increase to 58.0 MPa and 17.7, respectively, while the liquid metal are excluded from the contact interface between two tubes to be welded. The maximum plastic deformation is 18.1 mm at the given condition under the action of upsetting force. The experimental results illustrate that the microstructure of X65 FBW joints consists of massive ferrite, grain boundary pre-eutectic ferrite, pearlite, and widmannstatten, while the microstructure in heat-affected zone is fine ferrite and pearlite. The coarse grain size and gray spots in the butt joint severely decrease the tension strength and impact toughness.

MANUFACTURE INVESTIGATION OF CARTRIDGE WITH BOTTOM-MOST PART FLANGE BY DIRECT EXTRUSION WITH COUNTERPUNCH. REPORT 13. DETERMINATION OF DEFORMED STATE UNDER STRAITENED EXTRUSION IN FOURTH CENTRAL AREA OF PLASTIC DEFORMATION

2020 ◽  
Vol 0 (4) ◽  
pp. 43-51
Author(s):  
A. L. Vorontsov ◽  
◽  
I. A. Nikiforov ◽  
Keyword(s):  
Plastic Deformation ◽  
Plastic Flow ◽  
Central Area ◽  
Direct Extrusion ◽  
Deformed State ◽  
Cumulative Deformation ◽  
The Given ◽  
General Method

Formulae have been obtained that are necessary to calculate cumulative deformation in the process of straitened extrusion in the central area closed to the working end of the counterpunch. The general method of plastic flow proposed by A. L. Vorontsov was used. The obtained formulae allow one to determine the deformed state of a billet in any point of the given area. The formulae should be used to take into account the strengthening of the extruded material.

Friction Force and Stresses Analysis for Contact of Assembled Details

2006 ◽  
Vol 113 ◽  
pp. 334-338
Author(s):  
Z. Dreija ◽  
O. Liniņš ◽  
Fr. Sudnieks ◽  
N. Mozga
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Plastic Deformation ◽  
Friction Force ◽  
Sliding Friction ◽  
Friction Model ◽  
Contact Interface ◽  
Finite Element Program ◽  
Elastic Plastic ◽  
Element Program

The present work deals with the computation of surface stresses and deformation in the presence of friction. The evaluation of the elastic-plastic contact is analyzed revealing three distinct stages that range from fully elastic through elastic-plastic to fully plastic contact interface. Several factors of sliding friction model are discussed: surface roughness, mechanical properties and contact load and areas that have strong effect on the friction force. The critical interference that marks the transition from elastic to elastic- plastic and plastic deformation is found out and its connection with plasticity index. A finite element program for determination contact analysis of the assembled details and due to details of deformation that arose a normal and tangencial stress is used.

THE EFFECTS OF ELASTIC STIFFENING ON THE EVOLUTION OF THE STRESS FIELD WITHIN A SPHERICAL ELECTRODE PARTICLE OF LITHIUM-ION BATTERIES

2013 ◽  
Vol 05 (04) ◽  
pp. 1350040 ◽  
Author(s):  
WENBIN ZHOU ◽  
FENG HAO ◽  
DAINING FANG
Keyword(s):  
Stress Field ◽  
Lithium Ion Batteries ◽  
Internal Stress ◽  
Concentration Gradient ◽  
Concentration Field ◽  
Lithium Ion ◽  
Coupling Model ◽  
Ion Concentration ◽  
Hysteresis Phenomenon ◽  
Mechanical Coupling

Poor cyclic performance of lithium-ion batteries is calling for efforts to study its capacity attenuation mechanism. The internal stress field produced in the lithium-ion battery during its charging and discharging process is a major factor for its capacity attenuation, research on it appears especially important. We established an electrochemical –mechanical coupling model with the consideration of the influence of elastic stiffening on diffusion for graphite anode materials. The results show that the inner stress field strongly depends on the lithium-ion concentration field, greater concentration gradients lead to greater stresses. The evolution of the stress field is similar to that of the concentration gradient but lags behind it, which shows hysteresis phenomenon. Elastic stiffening can lower the concentration gradient and increase elastic modulus, which are two major factors influencing the inner stress field. We conclude that the latter is more dominant compared to the former, and elastic stiffening acts to increasing the internal stress.

Analysis of Transient Thermal Stress of IGBT Module Based on Electrical-Thermal-Mechanical Coupling Model

2014 ◽  
Vol 986-987 ◽  
pp. 823-827
Author(s):  
Qing Yuan Zheng ◽  
Min You Chen ◽  
Bing Gao ◽  
Nan Jiang
Keyword(s):  
Thermal Stress ◽  
Stress Distribution ◽  
Uniform Distribution ◽  
Inelastic Strain ◽  
Coupling Model ◽  
Power Module ◽  
Mechanical Coupling ◽  
Fem Method ◽  
Igbt Module ◽  
Solder Layer

Reliability of IGBT power module is one of the biggest concerns regarding wind power system, which generates the non-uniform distribution of temperature and thermal stress. The effects of non-uniform distribution will cause failure of IGBT module. Therefore, analysis of thermal mechanical stress distribution is crucially important for investigation of IGBT failure mechanism. This paper uses FEM method to establish an electrical-thermal mechanical coupling model of IGBT power module. Firstly, thermal stress distribution of solder layer is studied under power cycling. Then, the effects of initial failure of solder layer on the characteristic of IGBT module is investigated. Experimental results indicate that the strain energy density and inelastic strain are higher which will reduce reliability and lifetime of power modules.

scholarly journals Effect of Backing Plate Materials in Micro-Friction Stir Butt Welding of Dissimilar AA6061-T6 and AA5052-H32 Aluminum Alloys

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 933
Author(s):  
SeongHwan Park ◽  
YoungHwan Joo ◽  
Myungchang Kang
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloys ◽  
Heat Loss ◽  
Butt Joint ◽  
Thin Plates ◽  
Butt Welding ◽  
Friction Stir ◽  
Backing Plate ◽  
Base Materials ◽  
Tilting Angle

Thin sheets of lightweight aluminum alloys, which are increasingly used in automotive, aerospace, and electronics industries to reduce the weight of parts, are difficult to weld. When applying micro-friction stir welding (μ-FSW) to thin plates, the heat input to the base materials is considerably important to counter the heat loss to the jig and/or backing plate. In this study, three different backing-plate materials—cordierite ceramic, titanium alloy, and copper alloy—were used to evaluate the effect of heat loss on weldability in the μ-FSW process. One millimeter thick AA6061-T6 and AA5052-H32 dissimilar aluminum alloy plates were micro-friction stir welded by a butt joint. The tensile test, hardness, and microstructure of the welded joints using a tool rotational speed of 9000 rpm, a welding speed of 300 mm/min, and a tool tilting angle of 0° were evaluated. The heat loss was highly dependent on the thermal conductivity of the backing plate material, resulting in variations in the tensile strength and hardness distribution of the joints prepared using different backing plates. Consequently, the cordierite backing plate exhibited the highest tensile strength of 222.63 MPa and an elongation of 10.37%, corresponding to 86.7% and 58.4%, respectively, of those of the AA5052-H32 base metal.

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