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Abstract

The simulation of engineering problems is quite often a complex task that can be time consuming. In this context, the use of Hyper Reduced Order Models (HROMs) is a promising alternative for real-time simulations. In this work, we study the design of HROMs for non-linear problems with a moving source. Applications to nonlinear phase change problems with temperature dependent thermophysical properties are particularly considered; however, the techniques developed can be applied in other fields as well.

A basic assumption in the design of HROMs is that the quantities that will be hyper-reduced are k-compressible in a certain basis in the sense that these quantities have at most k non-zero significant entries when expressed in terms of that basis. To reach the computational speed required for a real-time application, k must be small. This work examines different strategies for addressing hyper-reduction of the nonlinear terms with the objective of obtaining k-compressible signals with a notably small k. To improve performance and robustness, it is proposed that the different contributing terms to the residual are separately hyper-reduced. Additionally, the use of moving reference frames is proposed to simulate and hyper-reduce cases that contain moving heat sources. Two application examples are presented: the solidification of a cube in which no heat source is present and the welding of a tube in which the problem posed by a moving heat source is analysed.

Abstract

This paper deals with the numerical simulation of friction stir welding (FSW) processes. FSW techniques are used in many industrial applications and particularly in the aeronautic and aerospace industries, where the quality of the joining is of essential importance. The analysis is focused either at global level, considering the full component to be jointed, or locally, studying more in detail the heat affected zone (HAZ). The analysis at global (structural component) level is performed defining the problem in the Lagrangian setting while, at local level, an apropos kinematic framework which makes use of an efficient combination of Lagrangian (pin), Eulerian (metal sheet) and ALE (stirring zone) descriptions for the different computational sub-domains is introduced for the numerical modeling. As a result, the analysis can deal with complex (non-cylindrical) pin-shapes and the extremely large deformation of the material at the HAZ without requiring any remeshing or remapping tools. A fully coupled thermo-mechanical framework is proposed for the computational modeling of the FSW processes proposed both at local and global level. A staggered algorithm based on an isothermal fractional step method is introduced. To account for the isochoric behavior of the material when the temperature range is close to the melting point or due to the predominant deviatoric deformations induced by the visco-plastic response, a mixed finite element technology is introduced. The Variational Multi Scale method is used to circumvent the LBB stability condition allowing the use of linear/linear P1/P1 interpolations for displacement (or velocity, ALE/Eulerian formulation) and pressure fields, respectively. The same stabilization strategy is adopted to tackle the instabilities of the temperature field, inherent characteristic of convective dominated problems (thermal analysis in ALE/Eulerian kinematic framework). At global level, the material behavior is characterized by a thermo–elasto–viscoplastic constitutive model. The analysis at local level is characterized by a rigid thermo–visco-plastic constitutive model. Different thermally coupled (non-Newtonian) fluid-like models as Norton–Hoff, Carreau or Sheppard–Wright, among others are tested. To better understand the material flow pattern in the stirring zone, a (Lagrangian based) particle tracing is carried out while post-processing FSW results. A coupling strategy between the analysis of the process zone nearby the pin-tool (local level analysis) and the simulation carried out for the entire structure to be welded (global level analysis) is implemented to accurately predict the temperature histories and, thereby, the residual stresses in FSW.

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Abstract

"jats:p"Previous study carried out residual stress characterization for the welds of the high-temperature-section (superheater / reheater) lower headers of the bottom-supported heat-recovery steam generator (HRSG). Modeling the gas-tungsten arc, manual welding process considered only weld-lay for the ASTM A 335-Grade P22 finned-tube angle joint to the cylinder. Present study aims at indirectly assessing findings of previous analysis measuring maximum residual stress on the joint’s exservice material. To achieve that a tee similar to the previous was not available: for both experimental and numerical analyses present study considers a P22 circumferential “V”-groove butt joint on HRSG pipeline section, creep-operated for the same period and temperature as the previous case. In the experimental activity X-ray diffraction method (or alternatively, hole-drilling strain gage one) applies as close as possible to the weld, being residual stress maximum at the fusion boundary. Thermal analysis for the previous case also showed it keeps nearly constant during weld cooling, relaxing most during creep: after 200,000 hours of operation, welding-process simulation predicted a maximum residual stress of 70 MPa; tee-joint creep-analysis found out a maximum equivalent stress of 91 MPa. As for the sample withdrawal, dimensions should be sufficient to avoid any interference with measurement area. The experimental procedures should comply with the European standard EN 15305 on the matter (the American standard ASTM E 837 for the alternate method). Comparison of analysis results for the two cases, confirms tendencies previously found out in creep-behavior, though different equivalent stress contributions. Comparison of predicted and observed residual stress values should allow for validation of numerical models used in both welding process and stress analysis.

Abstract

The final motivation of the research in which is framed this work is to optimize the friction-stir welding, FSW, process and its implementation in conventional machining centers. The FSW process occurs in the solid state at high temperature and by severe plastic deformation (high deformation at high rate) of the material. In this work we have studied the behavior at high temperature and high deformation rates of metal matrix composite materials 2124Al-25%SiC and 6061Al-40%SiC. The plastic deformation capacity in the high temperature regime has been studied by tensile, compressive and torsion tests at temperatures in the interval 300-475ºC and high strain rates, at 1s-1 and above. Large plastic deformations have been obtained without the appearance of serious defects despite the high reinforcement content. The good behavior in the conditions studied presumes the good weldability by means of the FSW technique. On the other hand, the data of the microstructure have allowed determining some of the constants that appear in the creep equation. Finally, we have succeeded in explaining the creep behavior through models developed for this technique from the experimental results.