Numerical simulation of ultrasonic spot welding of superelastic NiTi alloys: Temperature distribution and deformation behavior

Ultrasonic spot welding (USW) has attracted increasing attention due to its high- throughput solid-state bonding mechanism, which shows great potential in the semiconductor and automotive industry for the joining of metal sheets. However, the short welding cycle makes it challenging to effectively monitor the temperature history and deformation of the workpieces during the USW process, especially for the materials with some special properties. In this study, a three-dimensional (3D) finite element analysis model for USW of superelastic NiTi shape memory alloy (SMA) with Cu interlayer was developed using ANSYS Workbench. The thermal-stress coupled phenomena including the heat generation and stress distribution during the welding process was simulated and analyzed. Firstly, the superelastic constitutive model of NiTi SMAs was constructed. The distribution of temperature and stress field was then obtained by thermal-stress analysis using the direct coupling method, and the superelasticity of SMAs was observed. The simulation results showed that the highest temperature occurred in the center of the welding area during USW, which is proportional to the welding time and inversely proportional to the clamping pressure. In addition, the maximum stress occurred at the center of the contact surface between upper NiTi and Cu interlayer. After that, the validity of the simulation results was verified by setting up a thermocouple temperature measurement platform to collect the temperature data, which exhibited a good agreement with the simulated results. The simulation procedure demonstrates its potential to predict temperature and stress distribution during USW process.

Battery-Free Shape Memory Alloy Antennas for Detection and Recording of Peak Temperature Activity

Economical sensing and recording of temperatures are important for monitoring the supply chain. Existing approaches measure the entire temperature profile over time using electronic devices running on a battery. This paper presents a simple, intelligent, battery-free solution for capturing key temperature events using the natural thermo-mechanical state of a Shape Memory Alloy (SMA). This approach utilizes the temperature-induced irreversible mechanical deformation of the SMA as a natural way to capture the temperature history without the need for electronic data logging. In this article, two-way SMA is used to record both high-temperature and low-temperature peak events. Precise thermo-mechanically trained SMA are employed as arms of the dipole antenna for Radio Frequency (RF) readout. The fabricated antenna sensor works at 1 GHz and achieves a sensitivity of 0.24 dB/°C and −0.16 dB/°C for recording temperature maxima and minima, respectively.

Reduced defect recovery in self-ion damaged W due to simultaneous deuterium exposure during annealing

Deuterium (D) plasma exposure during annealing of self-ion damaged tungsten (W) is shown to exhibit reduced defect recovery when compared to annealing without D plasma exposure. In these experiments, samples were first damaged with 20 MeV W ions. Next, samples were annealed either with or without simultaneous D2 plasma exposure. The simultaneous annealed samples were first decorated by D2 plasma at 383 K prior to ramping up to an annealing temperature of 473, 573, 673, or 773 K and held for 1 hour with concurrent plasma exposure. The vacuum annealed samples each had a corresponding temperature history but without D$_2$ plasma treatment. Finally, all samples were exposed to D2 plasma at 383 K to decorate any remaining defects. Nuclear reaction analysis (NRA) and thermal desorption spectroscopy (TDS) shows that the simultaneous plasma-exposed and annealed samples exhibited virtually no defect recovery at annealing temperatures of up to 673 K, and had higher D retention than found in the vacuum annealed samples. TDS results indicate that only the lowest detrapping energy defects recover at an 773~K anneal for the simultaneous plasma annealed samples, while the vacuum annealed samples showed defect recovery at all anneal temperatures. This experiment clearly demonstrates that D occupied defects can significantly reduce or eliminate defect annealing in W, and is consistent with the existence of synergistic plasma exposure/displacement damage effects in fusion-energy relevant plasma facing materials.

Effect of Phase Transformations on Scanning Strategy in WAAM Fabrication

Due to its high production rates and low cost as compared to other metal additive manufacturing processes, wire arc additive manufacturing (WAAM) has become an emerging technology in the manufacturing industry. However, the residual stress generation and part distortion hinder its widespread adoption because of the complex thermal build-histories of WAAM parts. One of the ways to alleviate this problem is to consider the effects of scan strategies as it directly influences the thermal history of the built part. Since WAAM itself is an evolved welding process and even though it is evident from welding studies that phase transformations directly affect the residual stresses in welded parts, it remains unclear how the consideration of phase transformations for different scan strategies will affect the residual stresses and distortions in the WAAMed parts. A FEM study has been performed to elucidate the effects of phase transformations on residual stresses and the distortion for different deposition patterns. The current findings highlight that for the fabrication of low-carbon martensitic steels: The consideration of phase transformations for line-type discontinuous patterns (alternate and raster) do not significantly affect the residual stresses. Consideration of phase transformations significantly affects residual stresses for continuous patterns (zigzag, in–out and out–in). To accurately simulate complex patterns, phase transformations should be considered because the patterns directly influence the temperature history of the built part and will thus affect the phase transformations, the residual stresses and the warpage. During the fabrication of WAAM parts, whenever possible, discontinuous line scanning patterns should be considered as they provide the part with uniform residual stress and distortion. The alternate line pattern has been found to be the most consistent overall pattern.

Rock Acoustics of Diagenesis and Cementation

We simulate the effects of diagenesis, cementation and compaction on the elastic properties of shales and sandstones with four different petro-elastical theories and a basin-evolution model, based on constant heating and sedimentation rates. We consider shales composed of clay minerals, mainly smectite and illite, depending on the burial depth, and the pore space is assumed to be saturated with water at hydrostatic conditions. Diagenesis in shale (smectite/illite transformation here) as a function of depth is described by a 5th-order kinetic equation, based on an Arrhenius reaction rate. On the other hand, quartz cementation in sandstones is based on a model that estimates the volume of precipitated quartz cement and the resulting porosity loss from the temperature history, using an equation relating the precipitation rate to temperature. Effective pressure effects (additional compaction) are accounted for by using Athy equation and the Hertz-Mindlin model. The petro-elastic models yield similar seismic velocities, despite the different level of complexity and physics approaches, with increasing density and seismic velocities as a function of depth. The methodology provides a simple procedure to obtain the velocity of shales and sandstones versus temperature and pressure due to the diagenesis-cementation-compaction process.

Equivalent method for obtaining concrete age on the basis of electrical resistivity

Concrete age is the time since the moment water is added to the cement, and the age of concrete comprehensively reflects the physical properties of the concrete when curing under standard conditions. For concrete under nonstandard conditions, its physical properties are directly related to both its age and temperature history. The equivalent age of concrete is the time at which concrete under nonstandard conditions reaches the same state as concrete under standard conditions. Most equivalent methods, such as the Nurse-Saul function and the Arrhenius function, are based on a maturity index. However, the accuracy of these methods breaks down when the curing temperature range is wide. In this paper, the electrical resistivity of concrete is used as the index to determine the equivalent age of concrete. This method is based on the assumption that concrete with the same mixture proportions has the same electrical resistivity when the maturity of the concrete is the same, regardless of the curing history. The proposed method is advantageous because it can be performed in real time and is nondestructive. To constantly measure the electrical resistivity of concrete, an automatic data acquisition system is developed to monitor the electrical resistivity of concrete and reduce the error caused by polarization as much as possible. Then, a model for predicting the electrical resistivity of concrete under different curing temperatures is proposed to conveniently calculate the equivalent coefficient. Finally, the results calculated by the proposed equivalent method are compared with those of the standard method (Nurse-Saul equation), and the results of the proposed model are found to be more reasonable.

Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Friction stir extrusion (FSE) is a novel solid-phase processing technique that consolidates and extrudes metal powders, flakes, chips, or billets into high-performance parts by plastic deformation, which has the potential to save substantial processing time and energy. Currently, most studies on FSE are experimental and only a few numerical models have been developed to explain and predict the complex physics of the process. In this work, a meshfree simulation framework based on smoothed particle hydrodynamics (SPH) was developed for FSE. Unlike traditional grid-based methods, SPH is a Lagrangian particle-based method that can handle severe material deformations, capture moving interfaces and surfaces, and monitor the field variable histories explicitly without complicated tracking schemes. These aspects of SPH make it attractive for the FSE process, where in situ evolution of field variables is difficult to observe experimentally. To this end, a 3-D, fully thermomechanically coupled SPH model was developed to simulate the FSE of aluminum wires. The developed model was thoroughly validated by comparing the numerically predicted material flow, strain, temperature history, and extrusion force with experimental results for a certain set of process parameters. The validated SPH model can serve as an effective tool to predict and better understand the extreme thermomechanical conditions during the FSE process.

Alpine peak pressure and tectono-metamorphic history of the Monte Rosa nappe: evidence from the cirque du Véraz, upper Ayas valley, Italy

The Monte Rosa nappe consists of a wide range of lithologies that record conditions associated with peak Alpine metamorphism. While peak temperature conditions inferred from previous studies largely agree, variable peak pressures have been estimated for the Alpine high-pressure metamorphic event. Small volumes of whiteschist lithologies with the assemblage chloritoid + phengite + talc + quartz record peak pressures up to 0.6 GPa higher compared to associated metapelitic and metagranitic lithologies, which yield a peak pressure of ca. 1.6 GPa. The reason for this pressure difference is disputed, and proposed explanations include tectonic mixing of rocks from different burial depths (mélange) or local deviations of the pressure from the lithostatic value caused by heterogeneous stress conditions between rocks of contrasting mechanical properties. We present results of detailed field mapping, structural analysis and a new geological map for a part of the Monte Rosa nappe exposed at the cirque du Véraz field area (head of the Ayas valley, Italy). Results of the geological mapping and structural analysis shows the structural coherency within the western portions of the Monte Rosa nappe. This structural coherency falsifies the hypothesis of a tectonic mélange as reason for peak pressure variations. Structural analysis indicates two major Alpine deformation events, in agreement with earlier studies: (1) north-directed nappe emplacement, and (2) south-directed backfolding. We also analyze a newly discovered whiteschist body, which is located at the intrusive contact between Monte Rosa metagranite and surrounding metapelites. This location is different to previous whiteschist occurrences, which were entirely embedded within metagranite. Thermodynamic calculations using metamorphic assemblage diagrams resulted in 2.1 ± 0.2 GPa and 560 ± 20 °C for peak Alpine metamorphic conditions. These results agree with metamorphic conditions inferred for previously investigated nearby whiteschist outcrops embedded in metagranite. The new results, hence, confirm the peak pressure differences between whiteschists and the metagranite and metapelite. To better constrain the prograde pressure–temperature history of the whiteschist, we compare measured Mg zoning in chloritoid with Mg zoning predicted by fractional crystallization pseudo-section modelling for several hypothetical pressure–temperature paths. In order to reach a ca. 0.6 GPa higher peak pressure compared to the metapelite and metagranite, our results suggest that the whiteschist likely deviated from the prograde burial path recorded in metapelite and metagranite lithologies. However, the exact conditions at which the whiteschist pressure deviated are still contentious due to the strong temperature dependency of Mg partitioning in whiteschist assemblages. Our pseudo-section results suggest at least that there was no dramatic isothermal pressure increase recorded in the whiteschist.

In-Process Monitoring of Temperature Evolution during Fused Filament Fabrication: A Journey from Numerical to Experimental Approaches

Fused filament fabrication (FFF), an additive manufacturing technique, unlocks alternative possibilities for the production of complex geometries. In this process, the layer-by-layer deposition mechanism and several heat sources make it a thermally driven process. As heat transfer plays a particular role and determines the temperature history of the merging filaments, the in-process monitoring of the temperature profile guarantees the optimization purposes and thus the improvement of interlayer adhesion. In this review, we document the role of heat transfer in bond formation. In addition, efforts have been carried out to evaluate the correlation of FFF parameters and heat transfer and their effect on part quality. The main objective of this review paper is to provide a comprehensive study on the in-process monitoring of the filament’s temperature profile by presenting and contributing a comparison through the literature.