Papers by Keyword: Numerical Analysis

Abstract: In order to study the influence of different initial topography on the molten pool flow under a moving heat source, the finite element analysis method was used to establish a two-dimensional transient model of laser polishing to simulate the evolution of the surface topography of the material during laser polishing. In the simulation process, a moving laser beam was used as the heat source, and the free surface of the actual material was profiled through a three-dimensional profiler. A very similar simulation model surface was constructed, coupled with the flow field and temperature field in the laser polishing process, and the capillary force was considered comprehensively. Combined with thermocapillary force. The results show that under the combined action of capillary force and thermocapillary force, the surface of the polished material has a peak-filling effect, which makes the surface of the material achieve a good polishing effect. The initial shape will affect the polishing effect, the greater the curvature, the faster the flow rate of the molten pool. In molten pools with large spatial curvatures, capillary forces dominate. Keywords: Laser polishing; molten pool; surface topography; numerical analysis; capillary force; thermocapillary force.

Abstract: The solidification temperature range was numerically analyzed to optimize nonequilibrium solidification behavior during ternary Ni-Cr-Al nickel-based single-crystal superalloy weld pool solidification with variation of laser welding conditions (either heat input or welding configuration). The distribution of solidification temperature range along the fusion boundary is beneficially symmetrical about the weld pool centerline in the (001)/[100] welding configuration. The distribution of solidification temperature range along the fusion boundary is detrimentally asymmetrical about the weld pool centerline in the (001)/[110] welding configuration. The stray grain formation and solidification cracking are preferentially confined to [100] dendrite growth region. [001] epitaxial growth region with columnar dendrite morphology is favored at the expense of undesirable [100] growth region with equiaxed dendrite morphology to facilitate essential single-crystal solidification with considerable reduction of heat input. The smaller heat input is used, the narrower solidification temperature range is thermodynamically promoted to reduce nucleation and growth of stray grain formation with decrease of constitutional undercooling ahead of dendrite tip and mitigate thermo-metallurgical factors for morphology instability and microstructure anomalies. Potential low heat input(both decreasing laser power and increasing welding speed) with (001)/[100] welding configuration decreases solidification temperature range to significantly minimize columnar/equiaxed transition (CET) and stray grain formation, and improve resistance to solidification cracking through microstructure control. On both sides of weld pool are imposed by the same heat input, while the solidification temperature range along the fusion boundary inside of [100] dendrite growth region on the right part of the weld pool is spontaneously wider than that of [010] dendrite growth region on the left part to increase solidification cracking susceptibility in the (001)/[110] welding configuration. Furthermore, another mechanism of solidification cracking as consequence of severe solidification behavior and anomalous microstructure with asymmetrical crystallographic orientation is therefore proposed. The theoretical predictions are well verified by experiment results. The useful and satisfactory numerical modeling is also available for other single-crystal superalloys during successful laser repair process without stray grain formation.

Abstract: Multicomponent dendrite growth is theoretically predicted to optimize solidification cracking susceptibility during ternary Ni-Cr-Al nickel-based single-crystal superalloy weld pool solidification. The distribution of dendrite trunk spacing along the weld pool solidification interface is clearly symmetrical about the weld pool centerline in beneficial (001)/[100] welding configuration. The distribution of dendrite trunk spacing along the weld pool solidification interface is crystallography-dependent asymmetrical from bottom to top surface of the weld pool in detrimental (001)/[110] welding configuration. The smaller heat input is used, the finer dendrite trunk spacing is kinetically promoted by less solute enrichment and narrower constitutional undercooling ahead of solid/liquid interface with mitigation of metallurgical contributing factors for solidification cracking and vice versa. Vulnerable [100] dendrite growth region is predominantly suppressed and epitaxial [001] dendrite growth region is favored to spontaneously facilitate single-crystal columnar dendrite growth and reduce microstructure anomalies with further reduction of heat input. Optimum low heat input (both lower laser power and higher welding speed) with (001)/[100] welding configuration is the most favorable one to avoid nucleation and growth of stray grain formation, minimize both dendrite trunk spacing and solidification cracking susceptibility potential, improve resistance to solidification cracking, and ameliorate weldability and weld integrity through microstructure modification instead of inappropriate high heat input (both higher laser power and slower welding speed) with (001)/[110] welding configuration. The dendrite trunk spacing in the [100] dendrite growth region on the right side of the weld pool is considerably coarser and grows faster than that within the [010] dendrite growth region of the left side in the (001)/[110] welding configuration to deteriorate weldability, although the welding conditions are the same on the either side. Furthermore, the alternative mechanism of crystallography-dependent solidification cracking as consequence of asymmetrical microstructure development and diffusion-controlled dendrite growth of γ phase is therefore proposed. The theoretical predictions are comparable with experiment results. The reliable model is also useful for welding conditions optimization for crack-free laser processing.

Abstract: Microchannel heat sink plays a vital role in removing a considerable amount of heat flux from a small surface area from different electronic devices. In recent times, the rapid development of electronic devices requires the improvement of these heat sinks to a greater extent. In this aspect, the selection of appropriate substrate materials of the heat sinks is of vital importance. In this paper, three boron-based ultra-high temperature ceramic materials (ZrB₂, TiB_2, and HfB₂) are compared as a substrate material for the microchannel heat sink using a numerical approach. The fluid flow and heat transfer are analyzed using the finite volume method. The results showed that the maximum temperature of the heat source didn’t exceed 355K at 3.6MWm^-2 for any material. The results also indicated HfB₂ and TiB₂ to be more useful as a substrate material than ZrB₂. By applying 3.6 MWm^-2 heat flux at the source, the maximum obtained surface heat transfer coefficient was 175.2 KWm^-2K^-1 in a heat sink having substrate material HfB₂.

Abstract: To improve the pressure-bearing capacity, a novel high-pressure die with cemented carbide as the first layer of supporting ring was designed. The novel high-pressure die increases the ultimate load-bearing capacity of the high-pressure die by increasing the pretension of the tungsten carbide cylinder. As the volume of the cemented carbide increases, the difficulty of manufacturing increases, therefore, to reduce the manufacturing difficulty of the cemented carbide supporting ring and reduce the shear stress of the supporting ring, the cemented carbide supporting ring is splited. And through reasonable derivation calculations, the calculation formula suitable for the optimal interference amount of the high-pressure die is obtained. The numerical analysis results show that: when a pressure of 6.2 GPa is applied on the inner wall of the tungsten carbide cylinder, high-pressure die mold that uses cemented carbide as the first layer of support ring (hereinafter referred to as double-layered cemented carbide novel high-pressure die) is lower than the ordinary high-pressure die in term of circumferential stress by 93.34%. In terms of von Mises stress by 21.4%, and term of maximum shear stress by 21.37%. The three principal stress images of the two molds are drawn, which proved that the double-layered hard alloy novel high-pressure die can fully exert the performance of the material and can withstand greater pressure.

Abstract: The thermal metallurgical modeling of alloying aluminum redistribution was further developed through couple of heat transfer model, dendrite selection model, multicomponent dendrtie grwoth model and nonequilibrium solidification model during three-dimensional nickel-based single-crystal superalloy weld pool solidification over a wide range of welding conditions (laser power, welding speed and welding configuration) to facilitate understanding of solidification cracking phenomena. It is indicated that the welding configuration plays more important role than heat input in aluminum redistribution. The bimodal distribution of solid aluminum concentration along the solid/liquid interface is crystallographically symmetrical about the weld pool centerline for (001) and [100] welding configuration, while the distribution of solid aluminum concentration along the solid/liquid interface is crystallographically asymmetrical throughout the weld pool for (001) and [110] welding configuration. The size of vulnerable [100] dendrite growth region is beneficially suppressed in favor of epitaxial [001] dendrite growth region through optimum low heat input (low laser power and high welding speed) to facilitate single-crystal dendrite growth for successful crack-free weld at the expense of shallow weld pool geometry. The overall aluminum concentration in (001) and [100] welding configuration is significantly smaller than that of (001) and [110] welding configuration regardless of heat input. Severe aluminum enrichment is confined to [100] dendrite growth region where is more susceptible to solidification cracking. Heat input and welding configuration are optimized in order to minimize the solidification cracking susceptibility and improve microstructure stability. The relationship between welding conditions and alloying aluminum redistribution are established for solidification cracking susceptibility evaluation. The higher heat input is used, the more aluminum enrichment is monotonically incurred by diffusion with considerable increase of metallurgical driving forces for morphology instability and microstructure anomalies to deteriorate weldability and vice versa. The mechanism of asymmetrical solidification cracking because of crystallography-dependent alloying redistribution is proposed. The theoretical predictions agree well with the experiment results. Moreover, the useful modeling is also applicable to other single-crystal superalloys with similar metallurgical properties during laser welding or laser cladding.

Abstract: The mathematical modeling of microstructure development is further extended through coupling of heat transfer model and columnar/equiaxed transition (CET) model during nickel-based single-crystal superalloy weld pool solidification with different welding conditions (laser power, welding speed and welding configuration). It is indicated that crystallographic orientation plays an important role in stray grain formation ahead of the solid/liquid interface on the basis of constitutional undercooling mechanism. (001) and [100] welding configuration promotes symmetrical distribution of microstructure morphology about the weld pool centerline that is favored for reduction of stray grain formation, while detrimental (001) and [110] welding configuration induces asymmetrical distribution of microstructure morphology with more stray grain formation and deteriorates the weldability. The mechanism of increasing stray grain formation due to misorientation of dendrite growth crystallography is proposed. Appropriate low heat inputs (low laser power or high welding speed) of solidification conditions prevents stray grain formation and vice versa, and suppress the size of vulnerable [100] dendrite growth region. Weld pool geometry, θ-φ of solid/liquid interface, morphology transition and stray grain formation on either side of weld are closely correlated. In order to eliminate stray grain formation through microstructure control, it is imperative to optimize the welding configurations for defect-free weld through useful welding configuration-microstructure map. The theoretical predictions are verified by the experiment results in a consistent way. In addition, the model is also applicable to other single-crystal superalloys with similar metallurgical properties by feasible laser welding or laser cladding.

Abstract: A finite element model of thermal coupling stress field during laser cladding plasma spraying of preset MCrAlY coating was constructed based on the finite element model of temperature field by using the indirect thermal coupling method in ANSYS finite element software. Moreover, stress field during laser cladding was analyzed. Through the constructed model, variation laws of stress field with time during laser cladding and cooling process could be mastered. Based on the stress field, the formation mechanism of cracks in laser cladding coating and influencing factors were further analyzed and some solutions to cracks of laser cladding coating were proposed.

Abstract: A finite element model of temperature field for plasma spraying preset MCrAlY coating during laser cladding was constructed using ANSYS parametric design language (APDL) in accordance to characteristics of preset laser cladding. Influencing laws of laser cladding parameters on temperature field were analyzed. Results show that laser power influences temperature field of cladding samples more than laser scanning speed. Experimental results agree well with simulation results, which prove the accuracy and reliability of the constructed calculation model of temperature field. Heating and cooling laws in the laser cladding process could be mastered through this calculation model. Research conclusions provide some references to optimization parameters in preparing high-performance laser cladding coatings.

Abstract: The thermal metallurgical modeling of liquid aluminum supersaturation was further developed through couple of heat transfer model, dendrite selection model, multicomponent dendrite growth model and nonequilibrium solidification model during three-dimensional nickel-based single-crystal superalloy weld pool solidification. The welding configuration plays more important role in supersaturation of liquid aluminum, morphology instability and nonequilibrium partition behavior. The bimodal distribution of liquid aluminum supersaturation along the solid/liquid interface is crystallographically symmetrical about the weld pool centerline in (001) and [100] welding configuration. The distribution of liquid aluminum supersaturation along the solid/liquid interface is crystallographically asymmetrical throughout the weld pool in (001) and [110] welding configuration. Optimum low heat input (low laser power and high welding speed) with (001) and [100] welding configuration is more favored to predominantly promote epitaxial [001] dendrite growth to reduce the metallurgical factors for solidification cracking than that of high heat input (high laser power and slow welding speed) with (001) and [110] welding configuration. The lower the heat input is used, the lower supersaturation of liquid aluminum is imposed, and the smaller size of vulnerable [100] dendrite growth region is incurred to ameliorate solidification cracking susceptibility and vice versa. The overall supersaturation of liquid aluminum in (001) and [100] welding configuration is beneficially smaller than that of (001) and [110] welding configuration regardless of heat input, and is not thermodynamically relieved by gamma prime γˊ phase. (001) and [110] welding configuration is detrimental to weldability and deteriorates the solidification cracking susceptibility because of unfavorable crystallographic orientations and alloying aluminum enrichment. The mechanism of asymmetrical solidification cracking because of crystallography-dependent supersaturation of liquid aluminum is proposed. The eligible solidification cracking location is particularly confined in [100] dendrite growth region. Moreover, the theoretical predictions agree well with the experiment results. The useful modeling is also applicable to other single-crystal superalloys with similar metallurgical properties for laser welding or laser cladding. The thorough numerical analyses facilitate the understanding of weld pool solidification behavior, microstructure development and solidification cracking phenomena in the primary γ phase, and thereby optimize the welding conditions (laser power, welding speed and welding configuration) for successful crack-free laser welding.