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Understanding the void defect formation mechanism and simultaneous predicting the tool service life in friction stir welding are critical for optimizing the welding parameters. However, the void defect formation mechanism in friction stir welding is not yet elucidated. In this study, a novel integrated thermal-fluid-structure coupling model of the friction stir welding process was proposed for simultaneous prediction of the weld formation and tool service life. A new non-uniform distribution model of the tool-workpiece contact pressure was proposed to describe the interaction between the tool and the workpiece. The void defect formation mechanism was quantitatively studied using the proposed integrated thermal-fluid-structure coupling model. The results show that the plastic material flows in the horizontal direction and can completely fill the cavity behind the tool for the welding condition of forming a sound weld. While the tool-workpiece contact interfacial frictional shear stress in the rear of the tool is decreased significantly which leads to a severe decrease in the plastic material flow velocity. Therefore, after bypassing the tool from the retreating side, the plastic material at the bottom of the weld stagnates, and void defect forms in the middle and lower part of the weld at the advancing side. The difference between the maximum and the minimum tool-workpiece contact pressure could serve as a numerical criterion to predict void defects. A sound joint is formed when the difference is lower than the critical value of 15 MPa, while a void defect is formed in the weld if it is higher than this critical value. The maximum equivalent stress acting on the tool is located at the pin root with severe stress concentration at a high welding speed. The front of the tool is subjected to tensile stress while its rear is subjected to compressive stress, therefore the tool is apt to fracture at its root under an inappropriate welding condition. The average normal stress of the tool varies periodically with its period consistent with the rotation period of the tool. The service life of the tool is decreased with the increase in welding speed and the decrease in rotation speed. The model is validated by experimental results.
Understanding the complicated interplay of the continuously evolving electrode materials in their inherent 3D states during the battery operating condition is of great importance for advancing rechargeable battery research.
In this regard, the synchrotron X-ray tomography technique, which enables non-destructive, multi-scale, and 3D imaging of a variety of electrode components before/during/after battery operation, becomes an essential tool to deepen this understanding. The past few years have witnessed an increasingly growing interest in applying this technique in battery research. Hence, it is time to not only summarize the already obtained battery-related Knowledge by using this technique, but also to present a fundamental elucidation of this technique to boost future studies in battery research. To this end, this review firstly introduces the fundamental principles and experimental Setups of the synchrotron X-ray tomography technique. After that, a user guide to ist application in battery research and examples of its applications in Research of various types of batteries are presented. The current review ends with a discussion of the future opportunities of this technique for next-generation rechargeable batteries research. It is expected that this review can enhance the reader’s understanding of the synchrotron X-ray tomography technique and stimulate new ideas and opportunities in battery research.