铝合金与槽型界面钢板的爆炸焊接

采用尺寸为4 mm×410 mm×410 mm的5083铝合金和尺寸为15 mm×400 mm×400 mm、表面开有燕尾槽的Q345钢板作为爆炸焊接的覆板与基板,根据理论公式得到铝合金-钢爆炸焊接下限后,选取其附近的参数进行爆炸焊接,再通过力学性能检测和微观形貌观察研究5083/Q345复合板界面的结合性能。实验结果表明:铝合金与钢在冶金结合和燕尾槽的挤压啮合共同作用下实现爆炸复合;铝合金与燕尾槽上底面、倾斜面和下底面的界面均呈平直状。铝合金与燕尾槽上底面、下底面以直接结合和不连续熔化块相结合的方式复合,而铝合金与燕尾槽倾斜面以连续熔化层的方式复合;复合板的剪切强度大于172 MPa,满足Al/Fe复合板结合强度的要求。     

Residual stress analysis near a cold expanded hole in a textured alclad sheet using X-ray diffraction

In this paper we present the methods of determination and the stress obtained at the periphery of a cold expanded hole in a 2024-T3 Alclad aluminum alloy sheet. The measurements in the aluminum clad were performed by the sin²Ψ method, taking experimental precautions to deal with the texture effects. In the core aluminum a special method had to be implemented to determine the stress values in a direction not accessible to the X-ray diffraction. The strains were measured in sample orientations selected according to the texture characteristics and stress factorsF _ij were used to calculate the stress tensor. TheF _ij values were determined assuming a quasi-isotropic material behavior, after concluding that the stress results were not significantly affected by factors calculated for textured material. The residual stress profile, both in the clad and in the sheet, shows a nearly axisymmetric stress state. Compressive stresses were observed near the periphery of the hole, with values that are higher on the exit than on the entrance face. Residual stresses were also higher in the hoop direction than in the radial direction. They decreased with the radial distance to the hole and affected the previous stress state over a distance of 6 mm. The plastic deformation induced by the cold expansion is well evidenced by the FWHM values, which in the affected zone decrease with increasing distance from the hole edge.     

Growth rate predictions of single- and multi-mode Richtmyer�CMeshkov instability with reshock

The single- and multi-mode Richtmyer–Meshkov instabilities (RMI) with reshock are numerically analyzed in two- and three-dimensional domains. Four different types of air/SF ₆ interface shapes are investigated in a shock tube configuration, and the predicted post-reshock growth rates are compared with available empirical models of Mikaelian’s (Physica D 36(3):343–347, 1989) and Charakhch’an’s (J Appl Mech Tech Phys 41(1):23–31, 2000). The simulation of 3D multi-mode RMI shows good agreement with a past experimental study, but other interface types (2D single-mode, 2D multi-mode and 3D single-mode) result in different growth rates after reshock. Parametric studies are therefore performed to investigate the sensitivities of the post-reshock growth rates to model the empirical parameters. For single-mode RMI configurations, the interface shape is found to be only a weak function of the post-reshock growth rate, as also predicted by previous reshock models. The post-reshock growth rate shows a linear correlation to the velocity jump due to reshock; however, it is only about a half of the prediction of Charakhch’an’s model even though the growth before reshock compares well with pre-reshock models. The 3D single-mode post-reshock RMI growth rate is nearly 1.6 times larger than the 2D single-mode RMI. The parametric studies of multi-mode RMI show two distinctly different growth rates depending on the mixing conditions at reshock. If the interface remains sharp at the time of reshock, the post-reshock growth rate is as large as the single-mode cases. However, if the interface is mixed due to non-linear interactions of bubbles and spikes, the growth rates becomes slow and independent of the interface shapes. Overall, this study provides new insights into the flow features of reshocked RMI for different initial perturbation types.     

High-speed visualisation of primary break-up of an annular liquid sheet

In this experimental study, a thin annular moving water sheet is placed between two annular co-flowing air streams. The shear at the interface gives rise to Kelvin–Helmholtz type instabilities and promotes development of a sinuous surface wave at the gas–liquid interface. The amplitude of the surface wave is amplified as it travels downstream of the nozzle exit until it ruptures forming spanwise and streamwise ligaments. The liquid sheet is illuminated with high-powered halogen lamps. High-speed imaging is used in this study to qualitatively visualise the structure of the spray—of particular interest is the evolution of the spray into a ligament structure during the primary break-up and the role the outer air stream plays in this process. Sequences of images with high temporal resolution (∼2,000 fps) are recorded for image processing and analysis of the surface waves and ligament formation. A preliminary analysis of the waveform of the outer gas–liquid interface of the annular liquid sheet over a range of conditions shows the sheet Strouhal number to increase with increasing gas to liquid momentum ratio. Electronic supplementary material The online version of this article (doi:) contains supplementary material, which is available to authorized users.     

On the Mutual Penetrations of Two Fluids Whose Interface is Accelerated by a Shock Wave

A shock tube experimental investigation and numerical simulations are undertaken to study the evolution of a perturbed interface of two different gases accelerated by a shock wave. The experimental method is based on a high-speed camera laser sheet diagnostic technique, and simulations are provided by our code CARBUR based on a finite volume discretization of Navier–Stokes’s equations. Two gas pairs are used to illustrate both the heavy/light (air/He) and the light/ heavy (air/SF₆) cases. Two simultaneous large initial perturbations, one positive and one negative, are tested for an incident shock wave Mach number in air of about 1.3. The thin membrane (less than 1 μ) which materializes the initial interface between the two test gases presents 2D perturbations whose wave number is close to 1 in order to rapidly reach the non-linear regime. The development of the perturbations is captured at a frequency of 10 kHz after the interface acceleration, and the experiments are complemented with a numerical simulation to validate the interface deformations. Results show an asymmetric mutual gas penetration increasing with the absolute value of the Atwood’s number. Furthermore, they confirm that the heavier gas penetrates the lighter as thin spikes and the lighter gas penetrates the heavier as large bubbles. Moreover, we show that the spike moves faster than the bubble in the heavy/light case and slightly faster in the light/heavy one. Finally, numerical and experimental results are in agreement.     

A Discontinuous Elastic Interface Transfer Model of Thin Film Nanoindentation

A new model of thin film indentation that accounted for an apparent discontinuity in elastic strain transfer at the film/substrate interface was developed. Finite element analysis suggested that numerical values of strain were not directly continuous across the interface; the values in the film were higher when a soft film was deposited on a hard substrate. The new model was constructed based on this discontinuity; whereby, separate weighting factors were applied to account for the influence of the substrate in strain developed in the film and vice-versa. By comparing the model to experimental data from thirteen different amorphous thin film materials on a silicon substrate, constants in each weighting factor were found to have physical significance in being numerically similar to the bulk scale Poisson’s ratios of the materials involved. When employing these material properties in the new model it was found to provide an improved match to the experimental data over the existing Doerner and Nix and Gao models. Finally, the model was found to be capable of assessing the Young’s modulus of thin films that do not exhibit a flat region as long as the bulk Poisson’s ratio is known.     

Inverse approach to identification of material parameters of cyclic elasto-plasticity for component layers of a bimetallic sheet

The present paper proposes a novel approach to the identification of the mechanical properties of individual component layers of a bimetallic sheet. In this approach, a set of material parameters in a constitutive model of cyclic elasto-plasticity are identified for the two layers of the sheet simultaneously by minimizing the difference between the experimental results and the corresponding results of numerical simulation. This method has an advantage of using the experimental data (tensile load vs strain curve in the uniaxial tension test and the bending moment vs curvature diagram in the cyclic bending test) for a whole bimetallic sheet but not for individual component layers. An optimization technique based on the iterative multipoint approximation concept is used for the identification of the material parameters. This paper describes the experimentation, the fundamentals and the technique of the identification, and the verification of this approach using two types of constitutive models (the Chaboche-Rousselier and the Prager models) for an aluminum clad stainless steel sheet.     

PREDICTION FOR FORMING LIMIT OF AL2024T3 SHEET BASED ON DAMAGE THEORY USING FINITE ELEMENT METHOD

This paper presents the application of anisotropic damage theory to the study of forming limit diagram of A12024T3 aluminum alloy sheet. In the prediction of limiting strains of the aluminum sheet structure, a finite element cell model has been constructed. The cell model consists of two phases, the aluminum alloy matrix and the intermetallic cluster. The material behavior of the aluminum alloy matrix is described with a fully coupled elasto-plastic damage constitutive equation. The intermetallic cluster is assumed to be elastic and brittle. By varying the stretching ratio, the limiting strains of the sheet under biaxial stretching have been predicted by using the necking criterion proposed. The prediction is in good agreement with the experimental findings. Moreover, the finite element cell model can provide information for understanding the microscopic damage mechanism of the aluminum alloy. Over-estimation of the limit strains may result if the effect of material damage is ignored in the sheet metal forming study.     

Flow near the permeable boundary of a porous medium: An experimental investigation using LDA

 Fluid flow at the interface of a porous medium and an open channel is the governing phenomenon in a number of processes of industrial importance. Traditionally, this has been modeled by applying the Brinkman’s modification of Darcy’s law to obtain the velocity profile in terms of an additional parameter known as the “apparent viscosity” or the “slip coefficient”. To test this ad hoc approach, a detailed experimental investigation of the flow was conducted using Laser Doppler Anemometry (LDA) in the close vicinity of the permeable boundary of a porous medium. The porous medium used in the experiments consisted of a network of continuous glass strands woven together in a random fashion. A Hele–Shaw cell was partially filled with a fibrous preform such that an open channel flow is coupled with the Darcy flow inside the preform through the permeable interface of the preform. The open channel portion of the Hele–Shaw cell also acts as an ideal porous medium of known in-plane permeability which is much higher than the permeability of the fibrous porous medium. A viscous fluid is injected at a constant flow rate through the above arrangement and a saturated and steady flow is established through the cell. Using LDA, steady state velocity profiles are accurately measured by traversing across the cell in the direction perpendicular to the flow. A series of experiments were conducted in which fluid viscosity, flow rate, solid volume fraction of the porous medium and depth of the Hele–Shaw cell were varied. For each and every case in which the conditions for Hele–Shaw approximation were valid, the depth of the boundary layer zone or the screening length inside the fibrous preform was found to be of the order of the channel depth. This is much larger as compared to the Brinkman’s prediction of the screening length which is of the order of √K, where K is the permeability of the fibrous porous medium. Based on this finding, we modified the boundary condition in the Brinkman’s solution and found that the velocity profile results compared well with the experimental data for the planar geometry and the fibrous preforms for volume fractions of 7%, 14% and 21% for Hele–Shaw cell depths of 1.6 and 3.175 mm. For a cell depth of 4.8 cm, in which the Hele–Shaw approximation was not valid, the boundary layer thickness or the screening length was found to be less than the mold or channel depth but was still much larger than the Brinkman’s prediction. Received: 10 May 1996 / Accepted: 26 August 1996     

Numerical simulation of titanium dissolution in the aluminum melt and synthesis of an intermetallic compound

Titanium dissolution in the aluminum melt and synthesis of an intermetallic compound at constant temperature and pressure are numerically simulated by the molecular dynamics method. Owing to titanium dissolution, the TiAl₃ intermetallic compound is formed near the interface between the titanium crystal and aluminum melt. Based on the theory of weak solutions, a mathematical model of titanium dissolution in the aluminum melt is constructed. Dependences of the diffusion coefficient, equilibrium concentration of titanium, and dissolution rate on temperature are obtained.     

Numerical modeling of thermophysical processes in laser-beam welding with formation of a vapor channel

A quasi-two-dimensional mathematical model of laser welding of plates made of a binary alloy with allowance for metal vaporization and formation of a vapor channel is developed. A difference algorithm and a computer code are designed on the basis of this model. Processes of melting, vaporization, and solidification of the alloy of butt-welded aluminum plates are considered numerically as an example. The shape and depth of the vapor channel and welding bath are calculated for given conditions of the radiation power and welding velocity. Based on semi-empirical relations and numerical data obtained, the characteristic size of the dendritic structure of the solidified melt is estimated. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 47, No. 5, pp. 88–96, September–October, 2006.     

Detection of plastic deformation patterns in a binary aluminum alloy

A whole-field, in-plane strain-mapping technique is evaluated for in situ monitoring of plastic deformation patterns in aluminum sheet metals. This technique is built on the recent developments in digital image correlation and improved data reduction procedures. The sensitivity and accuracy of the measured local strain variations are critically examined in terms of random and systematic experimental errors, free-surface roughening due to large plastic deformation and microscopic surface grain deformation. Tensile specimens made from an annealed Al−Mg alloy sheet metal are subjected to a large plastic and macroscopically uniform deformation, and no visible deformation patterns can be identified by direct surface observation. Using an incremental strain-mapping approach, the existence of nonstationary deformation bands in the annealed Al−Mg alloy is uncovered. The developed technique can be used to study the formation and evolution of plastic deformation patterns and their effect on tensile ductility, formability and surface finish of sheet metals.     

Fracture prediction in stretch forming using finite element simulation combined with ductile fracture criterion

Summary  A criterion for ductile fracture is introduced in the finite element simulation of sheet metal forming. From the calculated histories of stress and strain in each element, the fracture initiation site and the critical stroke are predicted by means of the ductile fracture criterion. The calculations are carried out for axisymmetric stretch forming of various aluminium alloy sheets and their laminates clad by mild steel sheets. The predictions so obtained are compared with experimental observations. The results show that the combination of the finite element simulation and the ductile fracture criterion enables the prediction of forming limit in a wide range of sheet metals. Accepted for publication 11 August 1996     

Experimental and numerical study on the falling film flow characteristics outside circular tube applied in floating liquefied natural gas (FLNG) under offshore conditions

Spiral wound heat exchanger (SWHE) relying on falling film evaporation and boiling is often used for FLNG. The performance of SWHE can be impacted strongly by the motion of the FLNG caused by the wave and typhoon. The falling film characteristics of SWHE outside circular tube are studied experimentally and numerically by a visualization experimental device based on the high-speed camera and a numerical model based on the dynamic grid. The results show that the wave crest of the liquid film moves to the titled side under offshore conditions. The evolution process of falling film flow pattern outside circular tube with the tilt angle of 9° can be divided into four stages: droplet formation and migration, liquid column formation and migration, liquid column coalescence, liquid sheet formation. A correlation permitting the prediction of the falling film flow pattern outside circular tube and the other one permitting the prediction of the average film thickness of circular tube are developed respectively based on the experimental and numerical data.     

Instability of a plane interface between two immiscible conducting viscous fluids in a normal electrostatic field

The dispersion relation for motions of a charged plane interface between two viscous incompressible immiscible conducting fluids is analyzed numerically for finite values of all the parameters involved. It is shown that in addition to the well-known aperiodic (Tonkes-Frenkel’ type) instability for certain values of the physical parameters an oscillatory instability with periodically growing amplitude may be realized in the system. Yaroslavl’. Translated from Izvestiya Rossiiskoi Akademii Nauk, Mekhanika Zhidkosti i Gaza, No. 6, pp. 116–123, November–December, 1998.     

Numerical modeling of slug flow initiation in a horizontal channels using a two-fluid model

This paper presents a methodology for modeling slug initiation and growth in horizontal ducts. Transient two-fluid equations are solved numerically using a class of high-resolution shock capturing methods. The advantage of this method is that slug formation and growth in a stratified regime can be calculated directly from the solutions to the flow field differential equations. In addition, by using high-resolution shock capturing methods that do not contain numerical diffusion, the discontinuity generated by slugging in the flow field can be modeled with good accuracy. The two-fluid model is shown to be well-posed mathematically only under certain conditions. Under these circumstances, the two-fluid model is capable of correctly predicting and modeling the flow physics. When ill-posed, an unbounded instability occurs in the flow field solution, and the instability amplitude increases exponentially with decreasing mesh sizes. This work shows that there are three zones associated with slug formation. In addition, long wavelength slugs are shown to initiate from short wavelength waves. These short waves are generated at the interface of the two phases by the Kelvin-Helmholtz hydrodynamic instability. The results obtained through numerical modeling show good agreement with experimental results.     

Penetration direction of a crack terminating at a bi-material interface obliquely

Crack penetration direction at a bi-material planar interface has been investigated numerically as a function of primary crack obliquity. Crack penetration angle prefers to follow the normal direction to the interface unless the crack obliquity is overly high. The retarded offset of the penetration angle from the direction normal to the interface is more apparent as Dunders’ parameter α decreases to −0.9, whereas the increase in α toward 0.9 fosters the offset of the penetration angle from the direction normal to the interface. This behavior has been well explained qualitatively in terms of the phase angle of the primary crack.     

Numerical homogenization of elastic and thermal material properties for metal matrix composites (MMC)

A two-scale material modeling approach is adopted in order to determine macroscopic thermal and elastic constitutive laws and the respective parameters for metal matrix composite (MMC). Since the common homogenization framework violates the thermodynamical consistency for non-constant temperature fields, i.e., the dissipation is not conserved through the scale transition, the respective error is calculated numerically in order to prove the applicability of the homogenization method. The thermomechanical homogenization is applied to compute the macroscopic mass density, thermal expansion, elasticity, heat capacity and thermal conductivity for two specific MMCs, i.e., aluminum alloy Al2024 reinforced with 17 or 30 % silicon carbide particles. The temperature dependency of the material properties has been considered in the range from 0 to \(500{\,}^\circ \mathrm {C}\), the melting temperature of the alloy. The numerically determined material properties are validated with experimental data from the literature as far as possible.     

A Two-Scale Model for Coupled Electro-Chemo-Mechanical Phenomena and Onsager’s Reciprocity Relations in Expansive Clays: II Computational Validation

In Part I Moyne and Murad [Transport in Porous Media 62, (2006), 333–380] a two-scale model of coupled electro-chemo-mechanical phenomena in swelling porous media was derived by a formal asymptotic homogenization analysis. The microscopic portrait of the model consists of a two-phase system composed of an electrolyte solution and colloidal clay particles. The movement of the liquid at the microscale is ruled by the modified Stokes problem; the advection, diffusion and electro-migration of monovalent ions Na⁺ and Cl⁻ are governed by the Nernst–Planck equations and the local electric potential distribution is dictated by the Poisson problem. The microscopic governing equations in the fluid domain are coupled with the elasticity problem for the clay particles through boundary conditions on the solid–fluid interface. The up-scaling procedure led to a macroscopic model based on Onsager’s reciprocity relations coupled with a modified form of Terzaghi’s effective stress principle including an additional swelling stress component. A notable consequence of the two-scale framework are the new closure problems derived for the macroscopic electro-chemo-mechanical parameters. Such local representation bridge the gap between the macroscopic Thermodynamics of Irreversible Processes and microscopic Electro-Hydrodynamics by establishing a direct correlation between the magnitude of the effective properties and the electrical double layer potential, whose local distribution is governed by a microscale Poisson–Boltzmann equation. The purpose of this paper is to validate computationally the two-scale model and to introduce new concepts inherent to the problem considering a particular form of microstructure wherein the clay fabric is composed of parallel particles of face-to-face contact. By discretizing the local Poisson–Boltzmann equation and solving numerically the closure problems, the constitutive behavior of the diffusion coefficients of cations and anions, chemico-osmotic and electro-osmotic conductivities in Darcy’s law, Onsager’s parameters, swelling pressure, electro-chemical compressibility, surface tension, primary/secondary electroviscous effects and the reflection coefficient are computed for a range particle distances and sat concentrations.     

Radiative shock solutions in the equilibrium diffusion limit

A semi-analytic solution is described for planar radiative shock waves in the equilibrium diffusion (1−T) limit. The solution requires finding numerically the root of a polynomial and integrating a nonlinear ordinary differential equation. This solution may be used as a test problem to verify computer codes that use the equilibrium–diffusion radiation model, or for more advanced radiation models in the optically-thick limit. The structure of the shock profiles is also discussed, including new accurate estimates on the conditions for continuous solutions. We also discuss how the Zel’dovich spike may be estimated from the equilibrium diffusion solution. Finally, results from a computer code are shown to compare well with a semi-analytic solution.