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Organisationseinheit der BAM
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Eingeladener Vortrag
- nein (64)
A fundamental study of physical mechanisms of wineglass-shaped fusion zone profile in laser melting
(2024)
The fusion zone geometry in laser melting processes e.g., laser welding and laser-based additive manufacturing, of metallic materials has commonly a wineglass-shaped profile which is critical to the grain orientation and stress distribution. Hereby, we adopt for the first time a decoupling work through a combination of multi-physics modelling and experiments to reveal the fundamental mechanisms of this special morphology. Two physicsbased easy-to-use metal vapour models are proposed to consider the vapour’s momentum and thermal effects separately. It is found that the direct laser energy absorption and Marangoni shear stress which are widely hypothesised to dominate the wineglass-shape formation show only a minor influence. The additional heating from the metallic vapour plume rather than its momentum impact contributes predominantly to the enlarging of the molten pool top region, resulting directly in the formation of the wineglass-shaped fusion zone. The generality of the plume heating effect is also validated in two types of materials (steel and Al) in a wide range of parameters.
Despite the advances in hardware and software techniques, standard numerical methods fail in providing real-time simulations, especially for complex processes such as additive manufacturing applications. A real-time simulation enables process control through the combination of process monitoring and automated feedback, which increases the flexibil- ity and quality of a process. Typically, before producing a whole additive manufacturing structure, a simplified experiment in form of a bead-on- plate experiment is performed to get a first insight into the process and to set parameters suitably. In this work, a reduced order model for the transient thermal problem of the bead-on-plate weld simulation is devel- oped, allowing an efficient model calibration and control of the process. The proposed approach applies the proper generalized decomposition (PGD) method, a popular model order reduction technique, to decrease the computational effort of each model evaluation required multiple times in parameter estimation, control and optimization. The welding torch is modeled by a moving heat source, which leads to difficulties separating space and time, a key ingredient in PGD simulations. A novel approach for separating space and time is applied and extended to 3D problems allowing the derivation of an efficient separated representation of the tem- perature. The results are verified against a standard finite element model showing excellent agreement. The reduced order model is also leveraged in a Bayesian model parameter estimation setup, speeding up calibrations and ultimately leading to an optimized real-time simulation approach for welding experiment using synthetic as well as real measurement data.
Despite the advances in hardware and software techniques, standard numerical methods fail in providing real-time simulations, especially for complex processes such as additive manufacturing applications. A real-time simulation enables process control through the combination of process monitoring and automated feedback, which increases the flexibility and quality of a process. Typically, before producing a whole additive manufacturing structure, a simplified experiment in the form of a beadon-plate experiment is performed to get a first insight into the process and to set parameters suitably. In this work, a reduced order model for the transient thermal problem of the bead-on-plate weld simulation is developed, allowing an efficient model calibration and control of the process. The proposed approach applies the proper generalized decomposition (PGD) method, a popular model order reduction technique, to decrease the computational effort of each model evaluation required multiple times in parameter estimation, control, and optimization. The welding torch is modeled by a moving heat source, which leads to difficulties separating space and time, a key ingredient in PGD simulations. A novel approach for separating space and time is applied and extended to 3D problems allowing the derivation of an efficient separated representation of the temperature.
The results are verified against a standard finite element model showing excellent agreement. The reduced order model is also leveraged in a Bayesian model parameter estimation setup, speeding up calibrations and ultimately leading to an optimized real-time simulation approach for welding experiment using synthetic as well as real measurement data.
It is proposed to model the experimentally observed weld pool boundary with superellipses (Lamé curves) and to find the unknown parameters of the curves using optimization methods. It has been shown experimentally that during laser welding of austenitic stainless steel with a thickness of 2 mm at a speed of 20 mm/s, the rear weld pool part has a shape close to triangular which can be accurately approximated by a superellipse. Analytical dependences of the trajectory and growth rate of the crystal and its cross-sectional area on the geometry of the rear weld pool part are obtained.
A method of solving the thermo-fluid dynamics problem is presented, enabling the prediction of the shape and dimensions of the weld pool during keyhole laser welding of thick plates. It is shown that the rear weld pool boundary can be satisfactorily approximated by a set of superellipses (Lamé curves). The presence of a convex rear weld pool boundary in the mid-plane has been observed experimentally and reproduced numerically. It was shown that in this zone the concentration of liquating impurities increases and the local solidification temperature decreases, contributing to the susceptibility to hot cracking.
Numerical and experimental assessment of liquid metal embrittlement in externally loaded spot welds
(2024)
Zinc-based surface coatings are widely applied with high-strength steels in automotive industry. Some of these base materials show an increased brittle cracking risk during loading. It is necessary to examine electrogalvanized and uncoated samples of a high strength steel susceptible to liquid metal embrittlement during spot welding with applied external load. Therefore, a newly developed tensile test method with a simultaneously applied spot weld is conducted. A fully coupled 3D electrical, thermal, metallurgical and mechanical finite element model depicting the resistant spot welding process combined with the tensile test conducted is mandatory to correct geometric influences of the sample geometry and provides insights into the sample’s time dependent local loading. With increasing external loads, the morphology of the brittle cracks formed is affected more than the crack depth. The validated finite element model applies newly developed damage indicators to predict and explain the liquid metal embrittlement cracking onset and development as well as even ductile failure.
Beim Unterpulverschweißen sind die Prozessgeräusche ein Indikator für eine gute Fügequalität. Diese Beurteilung kann i.d.R. nur von einer erfahrenen Fachkraft durchgeführt werden. Eine kürzlich entwickelte künstliche Intelligenz kann automatisch das akustische Prozesssignal anhand vortrainierter Merkmale klassifizieren und die Fügequalität anhand des Geräuschs beurteilen. Der Algorithmus, einmal richtig trainiert, kann den Prüfaufwand beim Unterpulverschweißen deutlich reduzieren.
Abstract
In the post-processing of large maritime components, a considerable amount of waste in the form of milling and grinding chips is produced. At the same time, additive manufacturing technologies have shown great potential in producing high-volume parts for maritime applications, allowing novel design approaches and short lead times. In this context, this study presents a sustainable approach to recycle and use aluminium bronze waste material, generated during post-processing of large cast ship propellers, as feedstock for laser-powder directed energy deposition. The recycling technology used to produce powder batches is inductive re-melting in combination with ultrasonic atomization. The derived metal powders are characterized using digital image analysis, powder flowability tests, scanning electron microscopy as well as energy dispersive X-ray spectroscopy. Compared to conventional metal powders produced by gas atomization, the recycled material shows excellent sphericity and a powder size distribution with a higher content of finer and coarser particles. Metallographic sections of deposited additively produced specimens show an increased hardness and reduced ductility, but also competitive densities and higher yield and ultimate tensile strength compared to cast material. The process chain shows high potential for the maritime sector to enable circular and sustainable manufacturing.
Die Wärmeverteilung des Lasers beim Laserstrahltiefschweißen ist für die Formgebung der Dampfkapillare und für die Schweißbaddynamik entscheidend. In dieser Arbeit werden die Laserwärmeverteilung und deren Einflüsse auf die Schweißbadtiefe sowie -breite numerisch anhand des Ray-Tracing-Verfahrens analysiert. Hierbei wird der La-serstrahl in mehreren Strahlenbündeln bzw. Subrays unterteilt. Diesbezüglich soll der Pfad der Subrays präzis be-rechnet werden, um die Dynamik der Dampfkapillare und des Schweißbades eines realen Schweißprozesses rich-tig abzubilden. Zu diesem Zweck beschäftigt sich die vorliegende Arbeit mit der Genauigkeitsverbesserung der Kontaktposition und der Reflexionsrichtung der Subrays auf der freien Oberfläche anhand der Level-Set-Methode. Um die Güte dieses Simulationsansatzes zu gewährleisten, wurde eine Gegenüberstellung mit den zwei klassischen Ray-Tracing-Verfahren mittels drei verschiedenen Benchmark-Testreihen durchgeführt. Anschließend wurden die Versuchsergebnisse zur Validierung der implementierten numerischen Ansätze verwendet. Im Rahmen dieser Arbeit kann es gezeigt werden, dass unterschiedliche Wärmeverteilung aufgrund der verschiedenen Ray-Tracing-Verfahren deutlich zu erkennen ist, welche wiederum die Schweißbaddynamik sowie die lokalisierte Dampfkapil-lardynamik stark beeinflussen. Ferner wurde es bestätigt, dass die implementierte Level-Set-Methode zu einer ge-naueren Ermittlung der Kontaktposition und der Reflexionsrichtung der Subrays und somit zu einer Verbesserung der simulierten Schmelzkontur führt.
Die Additive Fertigung gewinnt zunehmend an Bedeutung für die Verarbeitung von Kupferwerkstoffen im industriellen Umfeld. Hierbei wird verstärkt auf drahtförmige Ausgangswerkstoffe gesetzt, da diese Vorteile im Handling bieten, bereits aus der Schweißtechnik bekannt sind und sich zumeist durch geringere Beschaffungskosten auszeichnen. In den letzten Jahren entwickelte sich unter den drahtbasierten Verfahren der Directed-Energy-Deposition (DED) eine Prozessvariante unter Nutzung des Elektronenstrahls zur industriellen Marktreife. Dabei zeigt die Technologie Wire Electron Beam Additive Manufacturing (DED-EB) besondere Vorteile gegenüber anderen DED-Prozessen für die Anwendung an Kupfer. Um das Verfahren einem breiten Anwenderkreis in der Industrie zugänglich zu machen, fehlen jedoch Daten zu Leistungsfähigkeit, Prozessgrenzen und Anwendungsmöglichkeit- en. Die vorliegende Untersuchung beschäftigt sich mit dieser Problemstellung am Beispiel der Legierung CuSn1MnSi. Über mehrstufige Testschweißungen werden die physikalisch möglichen Prozessgrenzen ermittelt und Rückschlüsse über die Eignung der Parameter zum additiven Aufbau gezogen. An verschiedenen additiv gefertigten Probekörpern werden anschließend Kennwerte für Aufbaurate, Härte, Mikrostruktur, Oberflächenqualität sowie mechanische Festigkeitswerte ermittelt. Es zeigt sich, dass das die durch DED-EB hergestellten Proben, trotz des groben Gefüges sowie der thermischen Belastung im Aufbauprozess, in ihren Eigenschaften gut mit den Spezifikationen des Ausgangsmaterials übereinstimmen.