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- Friction stir welding (3)
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Understanding the influence of tool/pin shapes on the thermal and material flow behaviors in friction stir welding is of great significance for the optimal design of tool/pin based on a scientific principle. In this study, a numerical method based on computational fluid dynamics is employed to quantitatively analyze the thermo-physical phenomena in friction stir welding with two tools of different pin shapes (axisymmetrical conical tool and asymmetrical triflat tool). Through combining a steady state model with a transient state model, both the computation efficiency and accuracy are ensured. The boundary conditions of heat transfer and material flow are determined with considering a partial sticking/sliding contact condition at the toolworkpiece interface. The total heat generation, heat density and temperature distribution during the welding process with triflat tool are elucidated and compared with that of conical tool, and the material flow patterns and deformation regions of various pin orientations are illustrated in detail. It is found that the deformation zone caused by triflat tool is larger than that by conical tool, which is validated by the weld macrographs. The computed thermal cycles and peak temperature values at some locations are in good agreement with the experimentally measured ones.
The allergenic potential of airborne proteins may be enhanced via post-translational modification induced by air pollutants like ozone (O3) and nitrogen dioxide (NO2). The molecular mechanisms and kinetics of the chemical modifications that enhance the allergenicity of proteins, however, are still not fully understood. Here, protein tyrosine nitration and oligomerization upon simultaneous exposure of O3 and NO2 were studied in coated-wall flow-tube and bulk solution experiments under varying atmospherically relevant conditions (5–200 ppb O3, 5–200 ppb NO2, 45–96% RH), using bovine serum albumin as a model protein. Generally, more tyrosine residues were found to react via the nitration pathway than via the oligomerization pathway. Depending on reaction conditions, oligomer mass fractions and nitration degrees were in the ranges of 2.5–25% and 0.5–7%, respectively. The experimental results were well reproduced by the kinetic multilayer model of aerosol surface and bulk chemistry (KM-SUB). The extent of nitration and oligomerization strongly depends on relative humidity (RH) due to moisture-induced phase transition of proteins, highlighting the importance of cloud processing conditions for accelerated protein chemistry. Dimeric and nitrated species were major products in the liquid phase, while protein oligomerization was observed to a greater extent for the solid and semi-solid phase states of proteins. Our results show that the rate of both processes was sensitive towards ambient ozone concentration but rather insensitive towards different NO2 levels. An increase of tropospheric ozone concentrations in the Anthropocene may thus promote pro-allergic protein modifications and contribute to the observed increase of allergies over the past decades.
Simultaneous measurement of tool torque, traverse force and axial force in friction stir welding
(2013)
Simultaneous measurement of the tool torque, traverse force and axial force during friction stir welding process is of great significance to the understanding of the underlying process mechanism and the optimizing of the process parameters. Different from the traditional measurement methods using load cell or rotating component dynamometer, an indirect but economical methodology is used in this study for the simultaneous measurement of the traverse force, axial force and tool torque by monitoring the output torques of the servo motors and main spindle three-phase AC induction motor inside the FSW machine. The values of the traverse force, axial force and tool torque are determined under different welding conditions, and the influencing factors are examined. The measured results in friction stir welding of AA2024-T4 aluminum alloys at different combinations of tool rotation speed and welding speed lay foundation for process optimization.
The accurate prediction of the thermal energy generation and distribution in friction stir welding process is of great significance for the optimization of the process parameters and the understanding of the underlying mechanisms. In this study, a new method of integrative calculation and measurement is proposed to obtain the more reasonable values of the frictional coefficient and the slip rate, which are both used to characterize the heat generation rate at the tool-workpiece contact interfaces. A three-dimensional model is established to fully couple the energy generation, heat transfer and material flow in friction stir welding of aluminum alloys. The energy produced by both interfacial friction and plastic deformation are taken into consideration. The analysis accuracy of the thermal energy generation and distribution is improved, and the distribution features of thermal energy density in the vicinity of the tool are elucidated. The predicted peak temperature values at some locations are in agreement with the experimentally measured ones.