Thermomechanical behavior of casting sands: Experiments and elastoplastic modeling

The thermomechanical behavior of casting sands is discussed from an experimental and a theoretical point of view. Uniaxial compression tests at temperatures ranging from 20°C to 950°C and at different values of strain rate (ϵ = 10⁻² s⁻¹, ϵ = 10⁻³ s⁻¹ and ϵ = 10⁻⁴ s⁻¹) have been performed. They show that casting sands exhibit no strain rate effect in the temperature range 20–600°C, and that an elastoplastic model is well suited to describe the experimental results. Three thermoelastoplastic models, derived from Cam Clay and Hujeux models have been developed. These new models take into account the cohesion of the material. The physical parameters needed for these models have been obtained in the temperature range 20–300°C by using triaxial tests, uniaxial compression tests, isotropic compression tests and die pressing tests. An original triaxial apparatus has been built allowing a temperature of 800°C and a pressure of 4 MPa to be reached. In the temperature at which the parameters have been obtained (20–300°C), two additional triaxial compression tests at different confining pressures are used to check the validity of the thermoelastoplastic models used. The best quantitative results are obtained with the revised modified Cam Clay model.     

The Effect of Temperature on Anisotropy Properties of an Aluminium Alloy

The temperature influence on the mechanical behaviour during plastic deformation of an AA5754-O aluminium alloy has been investigated by several experimental tests. First, monotonous tensile tests were carried out from room temperature up to 200°C with a classical tensile machine and with a less conventional testing apparatus involving the heating of the sample by Joule effect. With this second testing apparatus, the strain fields and tensile curves were obtained in function of temperature by means of a non-contacting optical 3D deformation measuring system. Moreover, shear tests were performed in the same temperature range. It is shown that the anisotropy coefficients are rather constant within this temperature range, with a relative variation less than 8%. For both tensile and shear tests, the stress levels are similar at the beginning of straining at room temperature and 150°C, except that the Portevin?CLe Chatelier (PLC) phenomenon disappears at elevated temperature, and then evolves differently. At 200°C, the stress level is clearly below whatever the deformation. In the framework of drawing process, the formability of this alloy at temperatures higher than 150°C seems to be improved.     

Heat transfer mechanisms in poplar wood undergoing torrefaction

Torrefaction, a thermal treatment process of biomass, has been proved to improve biomass combustible properties. Torrefaction is defined as a thermochemical process in reduced oxygen condition and at temperature range from 200 to 300 °C for shorter residence time whereby energy yield is maximized, can be a bridging technology that can lead the conventional system (e.g. coal-fired plants) towards a sustainable energy system. In efforts to develop a commercial operable torrefaction reactor, the present study examines the minimum input condition at which biomass is torrefied and explores the heat transfer mechanisms during torrefaction in poplar wood samples. The heat transfer through the wood sample is numerically modeled and analyzed. Each poplar wood is torrefied at temperature of 250, 270, and 300 °C. The experimental study shows that the 270 °C-treatment can be deduced as the optimal input condition for torrefaction of poplar wood. A good understanding of heat transfer mechanisms can facilitate the upscaling and downscaling of torrefaction process equipment to fit the feedstock input criteria and can help to develop treatment input specifications that can maximize process efficiency.     

Laminar axisymmetric pure and saline water plumes

 In most studies concerning round laminar plumes in a uniform environment a linear relationship between fluid density and temperature has been used. However it is known that the density-temperature relationship for water is non-linear at low temperatures. In this study the problem of round laminar plume of pure and saline water has been investigated in the temperature range between 20 °C and 0 °C taking into account the nonlinearity between density and temperature. The results are obtained with the numerical solution of the boundary layer equations. It was found that the plume behavior is dependent on ambient temperature and the centerline axial velocity at maximum density temperature is approximately 10% lower than the corresponding value based on linear relation between density and temperature. Received on 22 November 1999     

Wireless strain and temperature measurement with radio telemetry

A line of miniature strain and temperature telemetry transmitters have been developed for measurements in areas where direct-wire connections are not possible. The units described are 8–16 cu cm in volume (0.5–1.0 cu in.) and operate over a 0°C to 150°C ambient-temperature range with up to 30,000g′s acceleration. Battery life with a battery about the same size as the transmitter ranges from 50 to 200 hr. There is no degradation in accuracy for a 25-percent variation in battery voltage. Two types of strain transmitters have been developed. Both have full-scale ranges adjustable from 500 to 5000 microstrain and accuracies of ±2 percent. The “static” unit has response from dc to 1 KHz and the “dynamic” transmitter handles 30 Hz to 20 KHz. There are also two types of temperature transmitters. One accepts a variety of thermistor sensors for various measurement ranges between ?100°C and +600°C with accuracies of ±1°C. The other accepts various thermocouple inputs and has an accuracy of ±2 percent of range. These transmitters have been employed for a variety of industrial and scientific measurements. Some of the successful applications include transmission of strain and temperature data directly from pistons of reciprocating engines and from the compressor turbines of fan-jet engines.     

Strain rate effects and temperature history effects for three different tempers of 4340 var steel

A series of experiments is described in which specimens of AISI 4340 VAR steel are deformed in shear at temperatures ranging from −190°C.to 20°C. The tests were performed in a torsional Kolsky (split-Hopkinson) bar at quasistatic and dynamic strain rates. Before testing, all the specimens were normalized, austenitized and tempered to hardnesses of 55, 44 or 33, on the Rockwell C scale. In addition to constant temperature and constant strain rate tests, a number of experiments were performed to study strain rate and temperature history effects in these three tempers. For this purpose a prestrain was imposed at one temperature and strain rate, followed by continued straining at a new temperature or at a new strain rate.Results provide stress-strain curves in shear for the three tempers of this steel. Temperature effects appear greater between −190°C and −50°C than between −50°C and room temperature, particularly for the 200°C temper, while the strain rate sensitivity is about the same as found in mild steel. History effects are quite small for the 600°C and 425°C tempers, even at large strains. However, for the 200°C temper a prestrain at −50°C followed by a temperature change to −190°C requires a higher flow stress than does deformation imposed entirely at the lower temperature. Anomalous history effects of this nature have been seen before in steels, although this is the first evidence for their association with a particular temper.     

The recrystallization technique for local plastic-zone observation in type 304 stainless steel in the temperature range of −196° to 950° C

The recrystallization technique has been extended for direct observation of plastic zone in Type 304 stainless steel in the temperature range of ?196° to 950°C. It can reveal plastic deformation with plastic strain above 0.02 in the range of ?196° to 850° C and that with plastic strain above 0.06 at 950°C. Results of plastic-zone observation in notched specimen in the range of ?196° to 950° C are presented to illustrate the technique's capability.     

Dynamic Equibiaxial Flexural Strength of Borosilicate Glass at High Temperatures

A novel high temperature ring-on-ring Kolsky bar technique was employed to investigate the dynamic equibiaxial flexural strength of borosilicate glass at temperatures ranging from room temperature up to 750°C. This technique provided non-contact heating of the glass specimen and prevented thermal shocks in the specimen. Experimental results at the loading rate of 22.5 MN/s showed significant temperature dependence on the flexural strength. To explore the mechanisms of this temperature effect, controlled surface cracks were introduced on the tensile surface of the glass specimens using a Vickers indentation technique. These surface cracks were then heat treated under the same thermal histories as those tested in the high temperature dynamic experiments. The evolution of crack morphologies at 200°C, 550°C and 650°C were examined. The results indicate that residual stress relaxation may play an important role in the strengthening below 200°C, while crack healing and blunting may account for the strengthening above 500°C.     

Dynamic rheological properties of a fumed silica grease

The thermo-rheological characteristics of a fumed silica lubricating grease in linear and nonlinear oscillatory experiments have been investigated. The material rheological behavior represents a soft solid being thermo-rheologically complex. There is an abnormal temperature dependency in the range of ??10 to 10 °C which is related to the phase transition of the base oil. The dynamic moduli data in linear viscoelastic envelop (LVE) have been modeled using mode-coupling theory (MCT) in the whole temperature range. Two main relaxation mechanisms can be identified through linear and nonlinear viscoelastic properties related to interaction of the primary particle and its neighbor particles as well as a slow relaxation process which represents the escape of this particle from its “cage”. Finally, it is demonstrated that the dominant yielding process in large amplitude oscillatory experiments can be explained based on either particle cage rupture (consistent with MCT framework) or particle “hopping” out of its cage proposed in soft glassy rheology (SGR) model. It will be discussed that the governing mechanism depends on the applied frequency.     

Elevated-temperature elastic moduli of 2024 aluminum obtained by a laser-pulse technique

Elastic waves were generated in slender polycrystalline 2024 aluminum rods by the deposition of laser energy into the ends of the rods with a Q-switched laser. The propagation velocities of the waves were measured in the temperature range of 22° to 500°C. The elastic moduli of the material determined from these wave-propagation measurements are compared with previously reported single-crystal and polycrystalline aluminum data at elevated temperatures. Elastic moduli for polycrystalline 2024 aluminum agree with other reported data below about 200°C. Above this temperature, the 2024 aluminum moduli were found to decrease more rapidly with temperature than did those for single-crystal aluminum, although not as drastically as has been previously reported for polycrystalline aluminum.     

A viscoplastic constitutive model for nickel-base superalloy,part 2: modeling under anisothermal conditions

In Part 2 of this study, extensive deformation tests were carried out on the nickel-base polycrystalline superalloy IN738LC under isothermal and anisothermal conditions between 450 and 950 °C. Under the isothermal conditions, the material showed almost no rate/time-dependency below 700 °C, while it showed distinct rate/time-dependency above 800 °C. Regarding the cyclic deformation, slight cyclic hardening behavior was observed when the temperature was below 700 °C and the imposed strain rate was fast, whereas in the case of the temperature above 800 °C or under slower strain rate conditions, the cyclic hardening behavior was scarcely observed. Unique inelastic behavior was observed under in-phase and out-of-phase anisothermal conditions: with an increase in the number of cycles, the stress at higher temperatures became smaller and the stress at lower temperatures became larger in absolute value although the stress range was approximately constant during the cyclic loading. In other words, the mean stress continues to evolve cycle-by-cycle in the direction of the stress at lower temperatures. Based on the experimental results, it was assumed that evolution of the variable Y that had been incorporated into a kinematic hardening rule in Part 1 of this study is active under higher temperatures and is negligible under lower temperatures. The material constants used in the constitutive equations were determined with the isothermal data, and were expressed as functions of temperature empirically. The extended viscoplastic constitutive equations were applied to the anisothermal cyclic loading as well as the monotonic tension, stress relaxation, creep and cyclic loading under the isothermal conditions. It was demonstrated that the present viscoplastic constitutive model was successful in describing the inelastic behavior of the material adequately, including the anomalous inelastic behavior observed under the anisothermal conditions, owing to the consideration of the variable Y.     

Rheological properties of gluten plasticized with glycerol: dependence on temperature, glycerol content and mixing conditions

The rheological behaviour of a gluten plasticized with glycerol has been studied in oscillatory shear. The mixing operation in a Haake batch mixer leads to a maximum torque for a level of specific energy (500–600 kJ/kg) and temperature (50–60 °C) quite independent of mixing conditions (rotor speed, mixing time, filling ratio). The gluten/glycerol dough behaves as a classical gluten/water dough, with a storage modulus higher than the loss modulus over the frequency range under study. A temperature increase induces a decrease of moduli, but the material is not thermorheologically simple. Glycerol has a plasticizing effect, which can be classically described by an exponential dependence. Mixing conditions influence the viscoelastic properties of the material, mainly through the specific mechanical energy input (to 2000 kJ/kg) and temperature increase (to 80 °C). Above 50 °C, specific mechanical energy highly increases the complex modulus. The aggregation of proteins, as evidenced by size-exclusion chromatography measurements, occurs later as the dough temperature reaches 70 °C. The nature of network interactions and the respective influence of hydrophobic and disulphide contribution is discussed. A general expression is proposed for describing the viscous behaviour of a gluten/glycerol mix, which could seem simplistic for such a complex rheological behaviour, but would remain sufficient for modelling the flow behaviour in a twin screw extruder. Received: 24 November 1997 Accepted: 28 April 1999     

On the effects of fluid temperature on hot wire characteristics

Subject of this paper is the effect of air temperature on the characteristics of a hot wire. Hot wires of four different lengths have been calibrated over a range of air temperatures from 20 °C to 60 °C. Finite wire length corrections that account for the effects of heat conduction at the ends have been applied to obtain the heat transfer characteristics of an infinitely long heated wire. The reduced data show that the dependence of the heat transfer from an infinitely long heated wire on fluid temperature is such that the Nusselt number vs. Reynolds number relationship, when these are evaluated with property values at the “film temperature”, do not collapse to a single curve. The reduced data show that a linear variation of the heat transfer with a temperature difference corresponds more closely to the experimental observations. Dedicated to Prof. Dr.-Ing. M. Fiebig's 60th birthday     

Mechanical behavior of Gamma-Met PX under uniaxial loading at elevated temperatures and high strain rates

Gamma titanium aluminides have received considerable attention over the last decade. These alloys are known to have low density, good high temperature strength retention and good oxidation and corrosion resistance. However, poor ductility and low fracture toughness have been the key limiting factors in the full utilization of these alloys. More recently, a new generation of gamma titanium aluminide alloys, commonly referred to as Gamma-Met PX, has been developed by GKSS, Germany. These alloys have been observed to have superior strength and better oxidation resistance at elevated temperatures when compared with conventional gamma titanium aluminides.The present paper discusses results of a study to understand the uniaxial mechanical behavior in both compression and tension of Gamma-Met PX at elevated temperatures and high strain rates. The compression and tensile tests are conducted using a modified Split-Hopkinson Bar apparatus at test temperatures ranging from room temperature to 900 °C and strain rates of up to 3500 s⁻¹. Under uniaxial compression, in the temperature range from room to 600 °C, the flow stress is observed to be nearly independent of test temperature. However, at temperatures higher than 600 °C thermal softening is observed at all strain rates with the rate of thermal softening increasing dramatically between 800 and 900 °C. The room temperature tensile tests show negligible strain-rate dependence on both yield stress and flow stress. With an increase in test temperature from room to 900 °C, the material shows a drop in both yield and flow stress at all levels of plastic strain. However, the measured flow stress is still higher when compared to nickel based super-alloys and other gamma titanium aluminides under similar test conditions. Also, no anomaly in yield stress is observed up to 900 °C.     

Numerical computation of natural convection in an isosceles triangular cavity with a partially active base and filled with a Cu–water nanofluid

This paper discusses the results of a study related to natural convection cooling of a heat source located on the bottom wall of an inclined isosceles triangular enclosure filled with a Cu water-nanofluid. The right and left walls of the enclosure are both maintained cold at constant equal temperatures, while the remaining parts of the bottom wall are insulated. The study has been carried out for a Rayleigh number in the range 10⁴ ≤ Ra ≤ 10⁶, for a heat source length in the range 0.2 ≤ ε ≤0.8, for a solid volume fraction in the range 0 ≤ ?≤0.06 and for an inclination angle in the range 0° ≤ δ≤45°. Results are presented in the form of streamline contours, isotherms, maximum temperature at the heat source surface and average Nusselt number. It is noticed that the addition of Cu nanoparticles enhances the heat transfer rate and therefore cooling effectiveness for all values of Rayleigh number, especially at low values of Ra. The effect of the inclination angle becomes more noticeable as one increases the value of Ra. For high Rayleigh numbers, a critical value for the inclination angle of δ = 15° is found for which the heat source maximum temperature is highest.     

Composite viscoelasticity in glassy,transitional and molten states

As part of a study of viscous and elastic behaviors, over a range of temperatures from below the glass transition up to the hot melt, we here report steady-shear viscosities at 0.007 to 13 s^?1 and at 160 to 220 °C of polystyrene containing 0 to 60% by mass of 0.18-micron diameter titanium dioxide particles. The materials were shearthinning without a yield stress, with a constant activation energy at constant stress, but having a shear-dependent activation energy at constant shear rate — proportional to the volume fraction of the polymer matrix. Superposition of the flow curves at different temperatures for the unfilled and filled systems was possible. All the data were represented by one equation with four parameters: 1) a shear stress coefficient (units Pa · s²); 2) a characteristic stress level for non-Newtonian behavior, independent of temperature and composition; 3) an activation energy at constant stress; and 4) an Einstein coefficient (or intrinsic viscosity of the filler). Other equations also fitted the data, but the others diverged widely when extrapolated.     

Characterization of mechanical properties of aluminum cast alloy at elevated temperature

The tensile response, the low cycle fatigue(LCF) resistance, and the creep behavior of an aluminum(Al) cast alloy are studied at ambient and elevated temperatures.A non-contact real-time optical extensometer based on the digital image correlation(DIC)is developed to achieve strain measurements without damage to the specimen. The optical extensometer is validated and used to monitor dynamic strains during the mechanical experiments. Results show that Young's modulus of the cast alloy decreases with the increasing temperature, and the percentage elongation to fracture at 100℃ is the lowest over the temperature range evaluated from 25℃ to 300℃. In the LCF test, the fatigue strength coefficient decreases, whereas the fatigue strength exponent increases with the rising temperature. The fatigue ductility coefficient and exponent reach maximum values at 100℃. As expected, the resistance to creep decreases with the increasing temperature and changes from 200℃ to 300℃.     

Experimental study of the effect of spray inclination on ultrafast cooling of a hot steel plate

The ultrafast cooling that occurs during high mass flux air-atomized spray impingement on a hot 6 mm thick stainless steel plate has been studied experimentally in terms of the nozzle inclination between 0° and 60°. The average mass flux of water used in the study accounts to 510 kg/m² s. The coolants used in the study are pure water and surfactant water of 600 ppm concentration. The initial temperature of the plate has been maintained at 900 °C, which is the temperature of a hot strip on run-out table in steel industry. The transient surface heat flux and temperature histories have been estimated by an inverse heat solver using measured temperature input data. Heat transfer results demonstrates that optimum cooling efficiency (~2.76 MW/m², 194 °C/s) for pure water has been achieved at 30° nozzle orientation. The inclined nozzle has not been found beneficial when surfactant water is used as the coolant.