Ingenieurwissenschaften und zugeordnete Tätigkeiten
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Eingeladener Vortrag
- nein (443)
The explosion regions of 1-propanol, 2-propanol, acetone and 1-butanol in air were measured in the presence of CO2, He, N2 and Ar in accordance with EN1839 method T at high temperatures and at atmospheric pressure. The experimental results show that 1-propanol, 2-propanol and acetone have very similar lower explosion limits (LELs). 1-Butanol shows a slightly wider explosion area near the LEL line. In addition, the explosion regions of all combustible/inert gas/air mixtures were calculated with the method of constant adiabatic flame temperature profiles (CAFTP), using the flame temperature profile along the explosion region boundary curve of each combustible/N2/air mixture as a reference to determine the explosion regions of combustible/inert gas/air mixtures with inert gases other than N2 at different initial temperatures. To calculate the explosion regions for systems containing He, the calculation method was modified to include the very different physical transport properties of He. Moreover, the procedure for calculating the apexes in the ternary explosion diagrams was modified. The calculation results show good agreement with the experimental results.
Modeling of silicon surface topographies induced by single nanosecond laser pulse induced melt-flows
(2019)
Irradiation with a single nanosecond laser pulse in the melting regime can result in a characteristic change in the surface morphology of crystalline silicon. This has been verified experimentally in a variety of situations, where dimple-shaped surface topographies are produced. In this work, the dimple height, depth, and width are modeled following and extending in a more rigorous manner the approach of Wood and Giles [Phys. Rev. B 23, 2923–2942 (1981)] and that of Schwarz-Selinger and coworkers [Phys. Rev. B 64, 155323 (2001)], upon varying the laser irradiation parameters such as peak energy density, pulse duration, and wavelength. This is achieved with numerical simulations of one-dimensional heat flow as input to the analytical fluid-flow equations.
The crystallization behavior of sodium ion conductive Na2MnP2O7 glass was examined to clarify the crystallization mechanism. The formation of thermodynamically metastable phase, layered Na2MnP2O7, at the surface of the glass occurred. Heat treatment at 430 °C for 3 h lead to surface crystals of Na2MnP2O7 oriented with the (101) direction perpendicular to the sample surface. As the heat treatment temperature increased, the glass-ceramic samples deformed, and the presence numerous micro bubbles due to dissolved water was detected.
Ca-, Sr-, and Ba-Based coordination polymers (CPs) were prepared mechanochemically by milling metal-hydroxide samples with anthranilic acid (oABAH). {[Ca(oABA)2(H2O)3]}n consists of one-dimensional polymeric chains that are further connected by a hydrogen-bonding network. {[Sr(oABA)2(H2O)2]·H2O}n is a one-dimensional CP in which water molecules bridge Sr2+ ions and increase the dimensionality by building an extended network. {[Ba(oABA)2(H2O)]}n crystallizes as a two-dimensional CP comprising one bridging water molecule. The cation radii influence the inorganic connectivity and dimensionality of the resulting crystal structures. The crystal structures were refined from powder X-ray diffraction data using the Rietveld method. The local coordination environments were studied via extended X-ray absorption fine structure (EXAFS) measurements. The compounds were further characterized using comprehensive analytical methods such as elemental analysis, thermal analysis, MAS NMR, imaging, and dynamic vapor sorption (DVS) measurements. Compounds 1, 2, and 3 exhibit small surface areas which decrease further after thermal annealing experiments. All compounds exhibit a phase transformation upon heating, which is only reversible in 3.
Eu2+ is used to replace toxic Pb2+ in metal halide perovskite nanocrystals (NCs). The synthesis implies injection of cesium oleate into a solution of europium (II) bromide at an experimentally determined optimum temperature of 130 ○C and a reaction time of 60 s. Structural analysis indicates the formation of spherical CsEuBr3 nanoparticles with a mean size of 43 ± 7 nm. Using EuI2 instead of EuBr2 leads to the formation of 18-nm CsI nanoparticles, while EuCl2 does not show any reaction with cesium oleate forming 80-nm EuCl2 nanoparticles.
The obtained CsEuBr3 NCs exhibit bright blue emission at 413 nm (FWHM 30 nm) with a room temperature photoluminescence quantum yield of 39%. The emission originates from the Laporte-allowed 4f7–4f65d1 transition of Eu2+ and shows a PL decay time of 263 ns.
The long-term stability of the optical properties is observed, making inorganic lead-free CsEuBr3 NCs promising deep blue emitters for optoelectronics.
CsCoO2, featuring a two-dimensional layered architecture of edge- and vertex-linked CoO4tetrahedra, is subjected to a temperature-driven reversible second-order phase transformation at 100 K, which corresponds to a structuralrelaxation with concurrent tilting and breathing modes of edge-sharing CoO4tetrahedra. In the present investigation, it was found that pressure induces a phase transition, which encompasses a dramatic change in the connectivity ofthe tetrahedra. At 923 K and 2 GPa, beta-CsCoO2 undergoes a first-order phasetransition to a new quenchable high-pressure polymorph,alpha-CsCoO2. It is built up of a three-dimensional cristobalite-type network of vertex-sharing CoO4 tetrahedra. According to a Rietveld refinement of high-resolution powderdiffraction data, the new high-pressure polymorph gamma-CsCoO2 crystallizes in the tetragonal space groupI41/amd:2 (Z= 4) with the lattice constants a= 5.8711 (1) and c= 8.3214 (2) A, corresponding to a shrinkage in volume by 5.7% compared with the ambient-temperature and atmospheric pressure-CsCoO2polymorph.The pressure-induced transition (beta>gamma) is reversible;-CsCoO2 stays metastable under ambient conditions, but transforms back to the-CsCoO2structure upon heating to 573 K. The transformation pathway revealed isremarkable in that it is topotactic, as is demonstrated through a clean displacive transformation track between the two phases that employs the symmetry oftheir common subgroupPb21a(alternative setting of space group No. 29 that matches the conventional-phase cell).
For metal-based additive manufacturing, sensors and measuring systems for monitoring of the energy source, the build volume, the melt pool and the component geometry are already commercially available. Further methods of optics, spectroscopy and non-destructive testing are described in the literature as suitable for in-situ application, but there are only a few reports on practical implementations.
Therefore, a new BAM project aims to develop process monitoring methods for the in-situ evaluation of the quality of additively manufactured metal components. In addition to passive and active thermography, this includes optical tomography, optical emission and absorption spectroscopy, eddy current testing, laminography, X-ray backscattering and photoacoustic methods. These methods are used in additive manufacturing systems for selective laser melting, laser metal deposition and wire arc additive manufacturing. To handle the sometimes huge amounts of data, algorithms for efficient preprocessing are developed and characteristics of the in-situ data are extracted and correlated to defects and inhomogeneities, which are determined using reference methods such as computer tomography and metallography. This process monitoring and fusion of data of different measurement techniques should result in a significant reduction of costly and time-consuming, destructive or non-destructive tests after the production of the component and at the same time reduce the production of scrap.
Here, first results of simultaneous measurements of optical emission spectroscopy and thermography during the laser metal deposition process using 316L as building material are presented. Temperature values are extracted from spectroscopic data by fitting of blackbody emission spectra to the experimental data and compared with results from a thermographic camera. Measurements with and without powder flow reveal significant differences between welding at a pristine metal surface and previously melted positions on the build plate, illustrating the significant influence of the partial oxidation of the surface during the first welding process on subsequent welding. The measurement equipment can either be mounted stationary or following the laser path. While first results were obtained in the stationary mode, future applications for online monitoring of the build of whole parts in the mobile mode are planned.
This research was funded by BAM within the focus area Material.
Additive manufacturing (AM) opens the route to a range of novel applications. However, the complexity of the manufacturing process poses a challenge to produce defect-free parts with a high reliability. Since process dynamics and resulting microstructures of AM parts are strongly influenced by the involved temperature fields and cooling rates, thermography is a valuable tool for process monitoring. Another approach to monitor the energy input into the part during process is the use of optical tomography.
Common visual camera systems reach much higher spatial resolution than infrared thermography cameras, whereas infrared thermography provides a much higher temperature dynamic. Therefore, the combined application increases the depth of information. Here, we present first measurement results using a laser beam melting setup that allows simultaneous acquisition of thermography and optical tomography from the same point of view using a beam splitter. A high-resolution CMOS camera operating in the visible spectral range is equipped with a near infrared bandpass filter and images of the build plate are recorded with long-term exposure during the whole layer exposing time. Thus, areas that reach higher maximum temperature or are at elevated temperature for an extended period of time appear brighter in the images. The used thermography camera is sensitive to the mid wavelength infrared range and records thermal videos of each layer exposure at an acquisition rate close to 1 kHz.
As a next step, we will use computer tomographic data of the built part as a reference for defect detection.
This research was funded by BAM within the focus area Materials.
Aktuell werden Prozessmonitoringsysteme in der additiven Fertigung (AM) zur Überwachung der Energiequelle, des Bauraums, des Schmelzbades und der Bauteilgeometrie zumindest im metallbasierten AM schon kommerziell angeboten. Weitere Verfahren aus den Bereichen der Optik, Spektroskopie und zerstörungsfreien Prüfung werden in der Literatur als geeignet für die in-situ Anwendung bezeichnet, es finden sich aber nur wenige Berichte über konkrete Umsetzungen in die Praxis.
Die Bundesanstalt für Materialforschung und -prüfung hat ein neues Projekt gestartet, dessen Ziel die Entwicklung von Verfahren des Prozessmonitorings zur in-situ Bewertung der Qualität additiv gefertigter Bauteile in AM-Prozessen mit Laser- bzw. Lichtbogenquellen ist. Verschiedene Verfahren der zerstörungsfreien Prüfung, wie Thermografie, optische Tomografie, optische Emissionsspektroskopie, Wirbelstromprüfung und Laminografie werden in verschiedenen AM-Prozessen zum Einsatz gebracht und die Ergebnisse fusioniert. Die evaluierten Ergebnisse werden mit Referenzverfahren wie Computertomografie und Ultraschall-Tauchtechnik verglichen. Ziel ist eine deutliche Reduzierung aufwändiger und zeitintensiver, zerstörender oder zerstörungsfreier Prüfungen nach der Fertigung des Bauteiles und zugleich eine Verringerung von Ausschussproduktion.
Hier wird das Projekt als Ganzes vorgestellt und der Fokus auf verschiedene Methoden der Temperaturmessung mit Hilfe der Thermografie gelegt. Anforderungen an die Messtechnik für verschiedene AM-Systeme werden diskutiert und erste experimentelle Ergebnisse werden präsentiert.
The project ProMoAM is presented. The goal of the project is to evaluate which NDT techniques or combination of techniques is suited for in-situ quality assurance in additive manufacturing of metals. To this end, also 3d-data fusion and visualization techniques are applied. Additional ex-situ NDT-techniques are used as references for defect detection and quantification. Feasability studies for NDT-techniques that are presently not applicable for in-situ use are performed as well.
The presentation gives a brief overview of the whole project and the different involved NDT-techniques.
Microbial modelling of sulfate-reducing bacteria (SRB) and methanogenic archaea (ME) using iron
(2019)
Sulfate reducing bacteria (SRB) and methanogenic archaea (MA) are commonly found in the oil and gas environments. The formation of hydrogen sulfide (HS-) is particularly concerning for the petroleum industry due to its corrosiveness. However, the activities of SRB are limited to the concentration of sulfate present in the environment, whereas methanogens can utilize substrates such as H¬2 for methanogenesis. MA is commonly found in sulfate-free environments, such as deep sediments, and are known to form interspecies electron transfer relationships with SRB. Recently, SRB and MA capable of microbiologically influenced corrosion (MIC) by using elemental iron as a direct electron source (EMIC) have gained increased attention. On the iron surface, EMIC-SRB can outcompete EMIC-MA in the presence of sulfate, but this changes as sulfate depletes. The formation of FeS on the metal surface can be further utilized by MA for methanogenesis as it provides a conductive path. However, the possible kinetics involved of the overall process are currently unknown.
We obtained a co-culture of EMIC-SRB and EMIC-MA to investigate the growth rates and electrical potential changes under different environmental conditions, including changes in pH, temperature and salinity. Results indicate that under neutral conditions and using iron as the sole substrate, methane production (up to 5 mM) starts after sulfate was depleted. Electrochemical measurements will be conducted on the co-culture under different conditions to determine the changes in the electrical potential in correlation with the sulfate and methane concentration. Fluorescence and electron microscope images of the biofilm structure will be used to visualize cell distribution and morphology. This study embarks the first step of understanding the relationship between EMIC-SRB and EMIC-MA. Such knowledge is important for the field of microbial electrophysiology and can be further explored for industrial applications.
Flow-back and produced waters from shale gas and shale oil fields contain high ammonium, which can be formed by methanogenic degradation of methylamines into methane and ammonium. Methylamines are added to fracturing fluid to prevent clay swelling or can originate from metabolism of the osmolyte triglycinebetaine (GB).
We analyzed field samples from a shale gas reservoir in the Duvernay Formation and from a shale oil reservoir in the Bakken formation in Canada to determine the origin of high ammonium. Fresh waters used to make fracturing fluid, early flow-back waters, and late flow back waters from the shale gas reservoir had increasing salinity of 0.01, 0.58, and 2.66 Meq of NaCl, respectively. Microbial community analyses reflected this fresh water to saline transition with halophilic taxa including Halomonas, Halanaerobium, and Methanohalophilus being increasingly present. Early and late flow-back waters had high ammonium concentrations of 32 and 15 mM, respectively.
Such high concentrations had also been found in the Bakken produced waters.
Enrichment cultures of Bakken produced waters in medium containing mono, di-, or trimethylamine, or triglycinebetaine (GB) converted these substrates into ammonium (up to 20 mM) and methane. The methylotrophic methanogen Methanohalophilus, which uses methylamines for its energy metabolism and uses GB as an osmolyte, was a dominant community member in these enrichments. Halanaerobium was also a dominant community member that metabolizes GB into trimethylamine, which is then metabolized further by Methanohalophilus. However, the micromolar concentrations of GB measured in shale reservoirs make them an unlikely source for the 1,000-fold higher ammonium concentrations in flow-back waters. This ammonium either originates directly from the reservoir or is formed from methylamines, which originate from the reservoir, or are added during the hydraulic fracturing process. These methylamines are then converted into ammonium and methane by halophilic methylotrophic methanogens, such as Methanohalophilus, present in flow-back waters.
According to the results of the experiments carried out, the following points can be concluded:
1. Exposure tests showed that specimens with the addition of SiO2 particles and polyaniline particles exhibit better corrosion resistance than specimens with the addition of only polyaniline particles or binder only.
2. Open circuit potential measurements showed that in the beginning of the experiments, both coatings had an open circuit potential 100 mV higher than carbon steel. Within one day of immersion, the potential of carbon steel increased significantly, indicating the formation of oxide layer. After extended exposure the carbon steel potential sat between PS1 (which had higher potential) and PS2 (which had a lower potential) and all three were in the range –600 mV to –500 mV vs Ag/AgCl.
3. Both coatings PS-1 and PS-2 were degraded with increasing exposure time, shown by the decrease of absolute impedance value at low frequency range after 2, 4, and 6 days exposure.
4. Potentiodynamic test was performed after 3 hours and 6 days exposure, and it was shown that the coating in the initial stage exhibited more passive behavior than the specimens exposed for 6 days.
Fireside Chat - Sharing PhD
(2019)
According to the results of the experiments carried out, the following points can be concluded:
1. Exposure tests showed that specimens with the addition of SiO2 particles and polyaniline particles exhibit better corrosion resistance than specimens with the addition of only polyaniline particles or binder only.
2. Open circuit potential measurements showed that in the beginning of the experiments, both coatings had an open circuit potential 100 mV higher than carbon steel. Within one day of immersion, the potential of carbon steel increased significantly, indicating the formation of oxide layer. After extended exposure the carbon steel potential sat between PS1 (which had higher potential) and PS2 (which had a lower potential) and all three were in the range –600 mV to –500 mV vs Ag/AgCl.
3. Both coatings PS-1 and PS-2 were degraded with increasing exposure time, shown by the decrease of absolute impedance value at low frequency range after 2, 4, and 6 days exposure.
4. Potentiodynamic test was performed after 3 hours and 6 days exposure, and it was shown that the coating in the initial stage exhibited more passive behavior than the specimens exposed for 6 days.
Geothermal energy is one of the most promising energy resources to replace fossil fuel. To extract this energy, hot fluids of various salts and gases are pumped up from a geothermal well having a certain depth and location. Geothermal wells in volcanic regions often contain highly corrosive CO2 and H2S gases that can be corrosive to the geothermal power-plants, which are commonly constructed of different steels, such as carbon steel. This research focuses on the corrosion behaviour of carbon steel exposed to an artificial geothermal fluid containing CO2 gas, using an artificial acidic-saline geothermal brine as found in Sibayak, Indonesia. This medium has a pH of 4 and a chloride content of 1,500 mg/L. Exposure tests were conducted for seven days at 70 °C and 150 °C to simulate the operating temperatures for low and medium enthalpy geothermal sources. Surface morphology and cross-section of the specimens from the above experiments were analysed using scanning electron microscope (SEM) and energy dispersive X-ray (EDX). Electrochemical tests via open circuit potential (OCP) and electrochemical impedance spectroscopy (EIS) were performed to understand the corrosion processes of carbon steel in CO2-containing solution both at 70 °C and 150 °C. Localized corrosion was observed to a greater extent at 70 °C due to the less protectiveness of corrosion product layer compared to that at 150 °C, where FeCO3 has a high corrosion resistance. However, a longer exposure test for 28 days revealed the occurrence of localized corrosion with deeper pits compared to the seven-day exposed carbon steel. In addition, corrosion product transformation was observed after 28 days, indicating that more Ca2+ cations incorporate into the FeCO3 structure.
Electrochemical deposition of polyaniline on carbon steel for corrosion study in geothermal solution
(2019)
Polyaniline has been widely developed for many applications, e.g. sensor, supercapacitor components, electrochromic devices, and anticorrosion pigments. Although the addition of polyaniline pigment in organic coatings has been an alternative for corrosion protection in industrial applications, the protection mechanism is still not fully understood. Herein in this study, as a part of the development of polyaniline/silicon dioxide coating for geothermal application, polyaniline has been deposited electrochemically on carbon steel surface in oxalic acid medium and tested in geothermal solution to understand the contribution of polyaniline to the corrosion protection of a polyaniline-based composite in the geothermal system. To observe the surface/interface reaction between the electrolyte and electrode surface during the electrochemical polymerization, electrochemical impedance spectroscopy (EIS) was applied after each cycle. For corrosion study in the geothermal application, an artificial geothermal solution was used with the composition of 1,500 mg/l Cl⁻, 20 mg/l SO₄²⁻, 15 mg/l HCO₃⁻, 200 mg/l Ca²⁺, 250 mg/l K⁺, and 600 mg/l Na⁺, and pH 4 to simulate a geothermal brine found in Sibayak, Indonesia. An electrochemical measurement was performed by monitoring the open circuit potential over seven days, with the interruption by EIS every 22 hours. The experiments were performed at room temperature and 150 °C (1 MPa) in an oxygen-free environment. Impedance spectra showed a reduction of the total impedance value of approximately 10 times for specimens measured at 150 °C compared to the specimens measured at room temperature, suggesting a less stable layer at high temperature.
The weld pool dynamics and shape play a fundamental role in keyhole mode welding. The presented work aims the experimental and numerical investigation of the influence of the weld pool characteristics on the formation of hot cracking. The experimental procedure allows recording the molten pool in the longitudinal section of a butt joint configuration of 15 mm thick structural steel and transparent quartz glass by using a high-speed video camera and two thermal imaging cameras. The observations show that the dimensions of the weld pool vary depending on the depth. The regions close to the surface form a teardrop-shaped weld pool. A bulge-region and its temporal evolution are observed approximately in the middle of the depth of the weld pool, where hot cracking appears. A numerical framework including models for the weld pool dynamics, global temperature field, transient stress state, crystal growth, diffusion and macro-segregation and subroutines for their one-way couplings is developed. The numerically obtained and experimentally observed results are in a good agreement. It is shown that the bulge-region leads to a delay in the solidification behavior, increased temporal tensile stresses and accumulation of impurities in the defect region and hence enhance the probability of hot cracking formation.
The geometrical characteristics of the weld end crater are commonly used for the validation of numerical results in welding simulation. A semi-analytical model calculating the cooling stage of the welding process after the moving energy source is turned off has been developed. A solution for various combinations of heat sources and workpieces has been found. The theoretical limits for the heat transfer of the absorbed energy during cooling in a thin plate and a semi-infinite body were studied. It is shown that after turning off the energy source, an additional melting of the base material in longitudinal direction may occur. The developed technique is applied to complete-penetration keyhole laser beam welding of a 2 mm thick austenitic chromium-nickel 316L steel plate at a welding speed of 20 mm/s and a laser power of 2.3 kW. The results show a theoretical increase of the weld end crater length in comparison to the length of the steady-state weld pool of up to 19 %. A shift of the centre of the end crater, in which the solidification of the liquid metal ends, towards the tail of the end crater relative to the axis of the heat source at the time of its termination, was computed. The speed and the direction of crystallization of the molten material in the weld pool and the end crater were found to be different. A good agreement between the computational results and the welding experiments was achieved.
A numerical framework simulation of the steady-state thermal behaviour in keyhole mode welding has been developed. It is based on the equivalent heat source concept and consists of two parts: computational thermo-fluid dynamics and heat conduction. The solution of the thermo-fluid dynamics problem by the finite element method for a bounded domain results in a weld pool interface geometry being the input data for a subsequent heat conduction problem solved for a workpiece by proposed boundary element method. The main physical phenomena, such as keyhole shape, thermo-capillary and natural convection and temperaturedependent material properties are taken into consideration. The developed technique is applied to complete-penetration keyhole laser beam welding of a 15 mm thick low-alloyed steel plate at a welding speed of 33 mm/s and a laser power of 18 kW. The fluid flow of the molten metal has a strong influence on the weld pool geometry. The thermo-capillary convection is responsible for an increase of the weld pool size near the plate surfaces and a bulge formation near the plate middle plane. The numerical and experimental molten pools, cross-sectional weld dimensions and thermal cycles of the heat affected zone are in close agreement.
This work aims to find the thermal cycles during and after fusion welding through simulation by first calculating the resulting local temperature field in the quasi-stationary part of the process. Here complete-penetration keyhole laser beam welding with a laser power of 18 kW on a 15 mm thick slab of a low-alloyed steel at a welding speed of 2 m/min is considered. In order to physically depict the laser material interaction a multi-physics numerical model including the effects of phase transformation, thermo-capillary convection, natural convection and temperature-dependent material properties up to evaporation temperature is developed. It uses a fixed keyhole geometry with a right truncated circular cone shape to introduce the laser beam energy to the workpiece. In a subsequent study, the resulting local temperature field is then used as an equivalent heat source in order to predict the unsteady thermal cycle during and after fusion welding. The translational movement of the laser beam through the workpiece is represented by a moving mesh approach. For the simulation, stationary heat transfer and fluid dynamics are described by a system of strongly coupled partial differential equations. These are solved with the commercial finite element software COMSOL Multiphysics 5.0. The results of the numerical simulation are validated by experiments, where the weld bead shapes and the thermal cycles show good correlation.
Der vorgestellte Modellierungsprozess dient zur Abschätzung einer geeigneten äquivalenten Wärmequelle und Berechnung des thermischen Verhaltens beim Laserstrahlschweißen. Die Methode Kombiniert die Vorteile von gägngigen Simulationsverfahren und reduziert die berücksichtigte Anzahl an physikalischen Aspekten und Kalibrierungsparameter. Durch die modellierten physikalischen Phänomene konnten die Informationen über die Strömung im Schmelzbad und dessen Einfluss auf die resultierende lokale Temperaturverteilung und folglich auf das transiente Temperaturfeld gewonnen werden. Dadurch wurde die Simulatioszeit(inkl. Kalibrierungsaufwand) auf weniger als einen Tag Rechenzeit verringert.
The shape of the weld pool in laser beam welding plays a major role to understand the dynamics of the melt and its solidification behavior. The aim of the present work was its experimental and numerical investigation. To visualize the geometry of the melt pool in the longitudinal section a butt joint configuration of 15 mm thick structural steel and transparent quartz glass was used. The weld pool shape was recorded by means of a high-speed video camera and two thermal imaging MWIR and VIS cameras. The observations show that the dimensions of the weld pool vary depending on the depth. The regions close to the surface form a teardrop shaped weld pool. A bulge-region and its temporal evolution were observed approximately in the middle of the depth of the weld pool. Additionally, a transient numerical simulation was performed until reaching a steady state to obtain the weld pool shape and to understand the formation mechanism of the observed bulging phenomena. A fixed keyhole with an experimentally obtained shape was used to represent the full-penetration laser beam welding process. The model considers the local temperature field, the effects of phase transition, thermo-capillary convection, natural convection and temperature-dependent material properties up to evaporation temperature. It was found that the Marangoni convection and the movement of the laser heat source are the dominant factors for the formation of the bulging-region. Good correlation between the numerically calculated and the experimentally observed weld bead shapes and the time-temperature curves on the upper and bottom surface were found.
The shape of the weld pool in laser beam welding plays a major role to understand the dynamics of the melt and its solidification behavior. The aim of the present work was its experimental and numerical investigation. To visualize the geometry of the melt pool in the longitudinal section a butt joint configuration of 15 mm thick structural steel and transparent quartz glass was used. The weld pool shape was recorded by means of a high-speed video camera and two thermal imaging MWIR and VIS cameras. The observations show that the dimensions of the weld pool vary depending on the depth. The regions close to the surface form a teardrop shaped weld pool. A bulge-region and its temporal evolution were observed approximately in the middle of the depth of the weld pool. Additionally, a transient numerical simulation was performed until reaching a steady state to obtain the weld pool shape and to understand the formation mechanism of the observed bulging phenomena. A fixed keyhole with an experimentally obtained shape was used to represent the full-penetration laser beam welding process. The model considers the local temperature field, the effects of phase transition, thermo-capillary convection, natural convection and temperature-dependent material properties up to evaporation temperature. It was found that the Marangoni convection and the movement of the laser heat source are the dominant factors for the formation of the bulging-region. Good correlation between the numerically calculated and the experimentally observed weld bead shapes and the time-temperature curves on the upper and bottom surface were found.
The geometrical characteristics of the weld end crater are commonly used for the validation of numerical results in welding simulation. A semi-analytical model calculating the cooling stage of the welding process after the moving energy source is turned off has been developed. A solution for various combinations of heat sources and workpieces has been found. The theoretical limits for the heat transfer of the absorbed energy during cooling in a thin plate and a semi-infinite body were studied. It is shown that after turning off the energy source, an additional melting of the base material in longitudinal direction may occur. The developed technique is applied to complete-penetration keyhole laser beam welding of a 2 mm thick austenitic chromium-nickel 316L steel plate at a welding speed of 20 mm/s and a laser power of 2.3 kW. The results show a theoretical increase of the weld end crater length in comparison to the length of the steady-state weld pool of up to 19 %. A shift of the centre of the end crater, in which the solidification of the liquid metal ends, towards the tail of the end crater relative to the axis of the heat source at the time of its termination, was computed. The speed and the direction of crystallization of the molten material in the weld pool and the end crater were found to be different. A good agreement between the computational results and the welding experiments was achieved.
A novel approach for the reconstruction of an equivalent volumetric heat source from a known weld pool shape is proposed. It is based on previously obtained weld pool geometries from a steady-state thermo-fluid dynamics simulation. Hereby the weld pool dimensions are obtained under consideration of the most crucial physical phenomena, such as phase transformations, thermo-capillary convection, natural convection and temperature-dependent material properties. The algorithm provides a time and calibration efficient way for the reproduction of the weld pool shape by local Lamé curves. By adjusting their parameters, the identification of the finite elements located within the weld pool is enabled. The heat input due to the equivalent heat source is assured by replacing the detected nodes’ temperature by the melting temperature.
The model offers variable parameters making it flexible and adaptable for a wide range of workpiece thicknesses and materials and allows for the investigation of transient thermal effects, e.g. the cooling stage of the workpiece. The calculation times remain acceptably short especially when compared to a fully coupled process simulation. The computational results are in good agreement with performed complete-penetration laser beam welding experiments.
A numerical framework for simulation of the steady-state thermal behaviour in keyhole mode welding has been developed. It is based on the equivalent heat source concept and consists of two parts: computational thermo-fluid dynamics and heat conduction. The solution of the thermo-fluid dynamics problem by the finite element method for a bounded domain results in a weld pool interface geometry being the input data for a subsequent heat conduction problem solved for a workpiece by a proposed boundary element method. The main physical phenomena, such as keyhole shape, thermo-capillary and natural convection and temperature-dependent material properties are taken into consideration. The developed technique is applied to complete-penetration keyhole laser beam welding of a 15 mm thick low-alloyed steel plate at a welding speed of 33 mm/s and a laser power of 18 kW. The fluid flow of the molten metal has a strong influence on the weld pool geometry. The thermo-capillary convection is responsible for an increase of the weld pool size near the plate surfaces and a bulge formation near the plate middle plane. The numerical and experimental molten pools, cross-sectional weld dimensions and thermal cycles of the heat affected zone are in close agreement.
Приведено аналитическое решение задачи теплопроводности после прекращения действия подвижного источника теплоты для различных комбинаций источника и свариваемого тела. Показано, что после выключения источника возможно дополнительное плавление основного металла за счет перегретого жидкого металла сварочной ванны. Например, при лазерной сварке со сквозным проплавлением стальной пластины толщиной 2 мм длина кратера шва может быт на 19% больше установившейся длины сварочной ванны. Установлено, что центр кратера, в котором заканчивается затвердевание жидкого металла, смещен в сторону хвостовой части кратера относительно оси теплового источника в момент прекращения его действия. Скорость и направление кристаллизации металла сварочной ванны и кратера различны.
A novel cop olyme r based on supramolecular motif2,6-diaminopyridin e and water-soluble acrylamide, poly[N-(6-ace tamidopyridin-2-yl) acrylamide-co-acrylamide], was synthe-size d via rev ersible addi tion–fragmentation chain transfer (RAFT)polymerization with various monomer compositions. The thermo-respon sive behavior of the copolymers was studied by turbidime-try and dynamic light scattering (DLS). The obtained copolymersshowed an upper critical solution temperature (UCST)-typ e phasetransition behavior in water and electrolyte solution. The phasetransition temperature was found to increase with decreasingam ount of acrylamide in the copolymer and increasing concentra-tion of the solution. Furth ermore, the phase transition temperatureva ried in aqueous solutions of electrolytes according to the naturean d concentration of the electrolyte in accordance with theHoffmeister series. A dramatic solvent isotope effect on thetransition temperature was o bserved in this study, as the transitiontemperature was almost 10–12C higher in D2OthaninH2Oatthesame concentration and acrylamide co mposition. The size of theaggregates below the transition temperature was larger in D2Ocompared to that in H2O that can be explained by deuterium iso-tope effect. The thermoresponsive behavior of the copolymers wasalso investigated in different cell medium and found to be exhibitedUCST-type phase transition behavior in different cell medium.Such behavior of the copo lyme rs can be useful in many a pplica-tions including biomedical, microfluidics, optical materials, and indrug delivery.
Explosion and decomposition limits of flammable and chemically unstable gases were determined experimentally in a dosed autoclave with varying ignition energy up to 1000 J. The ignition source was a lightning arc caused by an exploding wire igniter as described in EN 1839 B .. In case of methane only the upper explosion limit was influenced significantly by the ignition energy, whereas the lower explosion limit was constant. In case of R32 however. it was the lower explosion limit that was influenced significantly by the ignition energy and not the upper explosion limit. A particularly strong dependency from the ignition energy was found for the decomposition limits of the chemically unstable gases in nitrogen.
Die Explosionsbereiche für Dreistoffsysteme aus Brennstoff, Inertgas und Luft wurden nach dem Modell der konstanten adiabatischen Flammentemperaturprofile berechnet. Für die Parametrisierung des halbempirischen Modells muss der Explosionsbereich für ein bestimmtes Dreistoffsystem aus Brennstoff, Inertgas und Luft bekannt sein. Dann lassen sich Explosionsbereiche desselben Brennstoffs mit einem beliebigen Inertgas und bei einer beliebigen Temperatur berechnen. Ergänzend zu früheren Arbeiten, in denen die Explosionsbereiche für Brenngase aus der homologen Reihe der Alkane und Alkene berechnet worden sind, wurden nun die Berechnungen für 1-Propanol, Aceton und Difluormethan durchgeführt. Als Inertgase wurden neben Stickstoff und Kohlendioxid auch die Edelgase Argon und Helium berücksichtigt. Für die Berechnung der Explosionsbereiche in Systemen mit Helium, ist das Modell erweitert worden, so dass auch die Transporteigenschaften (d.h. Wärmeleitfähigkeit, Diffusionskoeffizient) der Komponenten berücksichtigt werden. Weiterhin ist eine Möglichkeit zur praxisnahen Berechnung der Spitze des Explosionsbereichs implementiert worden. Die Ergebnisse zeigen insgesamt, dass die Berechnung der Explosionsbereiche für Alkohole, Ketone und halogenierte Kohlenwasserstoffe mit ähnlicher Genauigkeit wie für Alkane und Alkene möglich ist. Die vorgenommenen Modifikationen sind geeignet, um auch eine Berechnung für Gasgemische mit Helium durchzuführen, dessen starke inertisierende Wirkung im Vergleich zu den Inertgasen Argon oder Stickstoff vor allem auf den stark unterschiedlichen Transporteigenschaften beruht. Für die Analyse der physikalischen Vorgänge, die zur Zündung führen, ist eine spezielle Kontaktvorrichtung entwickelt worden. Damit können die Entladungen > 200 µm Länge und mit einer Dauer von > 500 µs an einer bestimmbaren Position erzeugt und untersucht werden.
Für die Entladungen an der Zündgrenze bei niedrigen Spannungs- und Stromwerten (max. 30 V, 30 bis 100 mA Konstantstrombegrenzung) sind die Bedingung für die Erzeugung ermittelt worden. Das sind die Rauheit auf der Kontaktoberfläche, die langsame Kontaktöffnungsbewegung und eine geeignet regelnde Spannungsquelle mit Konstantstrombegrenzung. Damit sind für diese Entladungen an der Zündgrenze die Strom-Spannungs-Kennlinie, das Spektrum mit dominierenden Linien von Cadmium-Metalldampf sowie die Temperaturverläufe ermittelt worden.
Explosion and decomposition limits of flammable and chemically unstable gases were determined experimentally in a closed autoclave with an ignition energy higher than the standard 10 J a 20 J. The ignition source was a lightning arc caused by an exploding wire igniter as described in EN 1839 B. With a newly developed ignition system a graded ignition energy between 3 J and 1000 J was generated. Different types of gases were studied with this ignition system: methane as a typical fuel gas and reference gas for some standards for explosion limit determination, the refrigerant R32 (difluoromethane) as a mildly flammable gas with low burning velocity and high minimum ignition energy compared with methane as well as the chemical unstable gases acetylene, nitrous oxide and ethylene oxide, which can decompose explosively in the absence of air or other oxidizers. It was found that the influence of strong ignition sources on explosion and decomposition limits can be very different for different systems. In case of methane only the upper explosion limit was influenced significantly by the ignition energy, whereas the lower explosion limit was constant. In a standard test vessel with an inner volume of 14 dm3 it was difficult to quantify the upper explosion limit of methane exactly with the strong ignition source, because the explosion pressure did not increase abruptly near the explosion limit, but steadily over a large concentration range. Probably a larger explosion vessel is more appropriate in this case. In case of R32 however, it was the lower explosion limit that was influenced significantly by the ignition energy and not the upper explosion limit. A particularly strong dependency from the ignition energy was found for the decomposition limits of the chemically unstable gases in nitrogen. Here special regard is necessary in practical applications, if uncommonly strong ignition sources cannot be excluded.
Despite of the significant advances in additive manufacturing (AM) process optimization there is still a lack of experimental results and understanding regarding the mechanical behavior and its relationship with the microstructural features of AM-parts, especially in loading conditions typical for safety-relevant applications. Within the scope of the presented ongoing investigations, a basic microstructural characterization, tensile tests at room and elevated temperature (400°C) as well as a characterization of the fatigue behavior of additively manufactured Ti-6Al-4V in the low cycle fatigue regime are carried out in the as-built state. After failure, different techniques are used to describe the failure mechanisms of the specimens. The AM-Specimens are provided by the Fraunhofer institute for production systems and design technology and investigated at the BAM following the philosophy of the TF-Project AGIL.
Despite of the significant advances in AM process optimization there is still a lack of experimental results and understanding regarding the mechanical behavior and microstructural evolution of AMparts, especially in loading conditions typical for safety-relevant applications e.g. in the aerospace or power engineering. Within the scope of the presented investigations, a characterization of the fatigue behavior of additively manufactured Ti-6Al-4V in the low cycle fatigue regime was carried out in the range of 0.3 to 1.0 % strain amplitude at room temperature, 250°C and 400°C. The Ti-6Al-4V specimens are machined out of lean cylindrical rods, which were fabricated using powder laser metal deposition (LMD) with an improved build-up strategy. The improved strategy incorporates variable track overlap ratios to achieve a constant growth in the shell and core area. The low-cycle-fatigue behavior is described based on cyclic deformation curves and strain-based fatigue life curves. The lifetimes are fitted based on the Manson-Coffin-Basquin relationship. A characterization of the microstructure and the Lack-of-Fusion (LoF)-defect-structure in the as-built state is performed using optical light microscopy and high-resolution computed tomography (CT) respectively. The failure mechanism under loading is described in terms of LoF-defects-evolution and crack growth mechanism based on an interrupted LCF test with selected test parameters. After failure, scanning electron microscopy, digital and optical light microscopy and CT are used to describe the failure mechanisms both in the longitudinal direction and in the cross section of the specimens. The fatigue lives obtained are comparable with results from previous related studies and are shorter than those of traditionally manufactured (wrought) Ti-6Al-4V. In this study new experimental data and understanding of the mechanical behavior under application-relevant loading conditions (high temperature, cyclic plasticity) is gained. Furthermore, a better understanding of the role of LoFdefects and AM-typical microstructural features on the failure mechanism of LMD Ti-6Al-4V is achieved.
Die Untersuchung und Charakterisierung der Entwicklung/Änderung der Mikrostruktur, der mechanischen Eigenschaften sowie der Lebensdauer additiv gefertigter metallischer Werkstoffe hat bisher, vor allem im Hinblick auf die komplexe Belastungsfälle bei sicherheitsrelevanten Anwendungen, mit der rasanten Entwicklung der Fertigungstechniken nicht Schritt gehalten. Im Rahmen dieser Arbeit wurde eine Charakterisierung des Ermüdungsverhaltens von additiv gefertigten TiAl6V4 im Low-Cycle-Fatigue Bereich (niederzyklische Ermüdung) nach Norm ISO 12206 mit Dehnungsamplituden von 0.3 bis zu 1.0 % und bei Raumtemperatur, 250°C und 400°C durchgeführt. Die TiAl6V4 Proben wurden aus zylindrischen Halbzeugen gefertigt, welche durch Laser-Pulver-Auftragsschweißen mit einer optimierten Aufbaustrategie hergestellt wurden. Die optimierte Aufbaustrategie beinhaltet variierende Spurüberlappungsgraden, die die Fertigung der dünnen zylindrischen Körper ohne weitere Ausgleichslagen ermöglicht. Das Werkstoffverhalten wird anhand von Wechselverformungskurven sowie einer Darstellung der Lebensdauer in einem Wöhler-Diagramm beschrieben. Ein Fitting der Lebensdauer-Daten erfolgt anhand der Manson-Coffin-Basquin Beziehung. Eine Eingangscharakterisierung der mikrostrukturellen Merkmale inklusive Bindefehler aus dem Herstellungsprozess wird durch Lichtmikroskopie und hochauflösende Computertomographie (CT) durchgeführt. Der Versagensmechanismus während der Belastung wird anhand von Zwischenuntersuchungen mit CT und einem unterbrochenen Versuch mit ausgewählten Versuchsparametern beschrieben. Nach dem Versagen wurden die Proben am REM, mit Lichtmikroskopie und mit CT fraktographisch in Längs- und Querrichtung untersucht. Die erfassten Lebensdauern sind ähnlich zu denen aus herkömmlichen Studien und liegen unter derjenigen von dem konventionell hergestellten (geschmiedeten) Werkstoff. In dieser Arbeit wurden für den untersuchten Werkstoff bei anwendungs- und sicherheitsrelevanten Belastungszuständen (hohe Temperaturen, zyklische Plastizität) neue experimentelle Daten und Kennwerte ermittelt und Verständnis über das mechanische Verhalten und die Entwicklung der Mikrostruktur aufgebaut. Darüber hinaus wurde Verständnis über die Rolle von Bindefehlern und anderen typisch für AM auftretenden Gefügemerkmalen auf das Versagensverhalten von DED-L TiAl6V4 gewonnen.
Die Untersuchung und Charakterisierung der Entwicklung/Änderung der Mikrostruktur, der mechanischen Eigenschaften sowie der Lebensdauer additiv gefertigter metallischer Werkstoffe hat bisher, vor allem im Hinblick auf die komplexe Belastungsfälle bei sicherheitsrelevanten Anwendungen, mit der rasanten Entwicklung der Fertigungstechniken nicht Schritt gehalten. Im Rahmen dieser Arbeit wurde eine Charakterisierung des Ermüdungsverhaltens von additiv gefertigten TiAl6V4 im Low-Cycle-Fatigue Bereich (niederzyklische Ermüdung) nach Norm ISO 12206 mit Dehnungsamplituden von 0.3 bis zu 1.0 % und bei Raumtemperatur, 250°C und 400°C durchgeführt. Die TiAl6V4 Proben wurden aus zylindrischen Halbzeugen gefertigt, welche durch Laser-Pulver-Auftragsschweißen mit einer optimierten Aufbaustrategie hergestellt wurden. Die optimierte Aufbaustrategie beinhaltet variierende Spurüberlappungsgraden, die die Fertigung der dünnen zylindrischen Körper ohne weitere Ausgleichslagen ermöglicht. Das Werkstoffverhalten wird anhand von Wechselverformungskurven sowie einer Darstellung der Lebensdauer in einem Wöhler-Diagramm beschrieben. Ein Fitting der Lebensdauer-Daten erfolgt anhand der Manson-Coffin-Basquin Beziehung. Eine Eingangscharakterisierung der mikrostrukturellen Merkmale inklusive Bindefehler aus dem Herstellungsprozess wird durch Lichtmikroskopie und hochauflösende Computertomographie (CT) durchgeführt. Der Versagensmechanismus während der Belastung wird anhand von Zwischenuntersuchungen mit CT und einem unterbrochenen Versuch mit ausgewählten Versuchsparametern beschrieben. Nach dem Versagen wurden die Proben am REM, mit Lichtmikroskopie und mit CT fraktographisch in Längs- und Querrichtung untersucht. Die erfassten Lebensdauern sind ähnlich zu denen aus herkömmlichen Studien und liegen unter derjenigen von dem konventionell hergestellten (geschmiedeten) Werkstoff. In dieser Arbeit wurden für den untersuchten Werkstoff bei anwendungs- und sicherheitsrelevanten Belastungszuständen (hohe Temperaturen, zyklische Plastizität) neue experimentelle Daten und Kennwerte ermittelt und Verständnis über das mechanische Verhalten und die Entwicklung der Mikrostruktur aufgebaut. Darüber hinaus wurde Verständnis über die Rolle von Bindefehlern und anderen typisch für AM auftretenden Gefügemerkmalen auf das Versagensverhalten von DED-L TiAl6V4 gewonnen.
Der Vortrag stellt ein neuartiges Korrosionsprüfverfahren für Zinküberzüge auf Basis gelartiger Elektrolyte vor und führt die Vorteile gegenüber konventionellen Prüfverfahren auf. Basierend auf den Ergebnissen wird die Idee für einen IGF-Projektantrag in Kooperation mit dem Fraunhofer IKTS vorgestellt.
Der Vortrag berichtet über die Auslagerung von Standardproben nach DIN EN ISO 9223 bis 9226 aus Zink, Stahl, Kupfer und Aluminium auf den verschiedenen atmosphärischen Bewitterungsständen der Bundesanstalt für Materialforschung und -prüfung (BAM). Im Vortrag werden die Masseverluste, Korrosionsgeschwindigkeiten und Korrosivitätskategorien der Standardproben im freibewitterten und überdachten Bereich nach einem Jahr vorgestellt und Unterschiede hinsichtlich der Atmosphärenbedingungen aufgezeigt. Freibewitterte Proben zeigen dabei deutliche Unterschiede hinsichtlich ihres Korrosionsverhaltens im Vergleich zu überdachten Proben. Die ermittelten Korrosivitätskategorien sind sowohl standort- als auch materialspezifisch.
Der Vortrag berichtet über die Auslagerung von Standardproben nach DIN EN ISO 9223 bis 9226 aus Zink, Stahl, Kupfer und Aluminium auf den verschiedenen atmosphärischen Bewitterungsständen der Bundesanstalt für Materialforschung und -prüfung (BAM). Im Vortrag werden die Masseverluste, Korrosionsgeschwindigkeiten und Korrosivitätskategorien der Standardproben im freibewitterten und überdachten Bereich nach einem Jahr vorgestellt und Unterschiede hinsichtlich der Atmosphärenbedingungen aufgezeigt. Freibewitterte Proben zeigen dabei deutliche Unterschiede hinsichtlich ihres Korrosionsverhaltens im Vergleich zu überdachten Proben. Die ermittelten Korrosivitätskategorien sind sowohl standort- als auch materialspezifisch.
Ein neuer Ansatz bei elektrochemischen Korrosionsuntersuchungen kann durch den Einsatz von gelartigen Elektrolyten als Alternative zu wässrigen Prüfelektrolyten beschritten werden. Gelartige Elektrolyte ermöglichen minimalinvasive Untersuchungen an natürlich gebildeten Zinkdeckschichten. Dadurch können korrosionsrelevante Kennwerte ermittelt werden, die Aussagen zur Deckschichtbildung und zur Stabilität von atmosphärisch gebildeten Deckschichten erlauben. In diesem Beitrag wird anhand verschiedener Untersuchungen an Reinzink der Mehrwert von gelartigen Elektrolyten für die Korrosionsforschung und -prüfung verdeutlicht. Darüber hinaus werden neue Erkenntnisse zur Deckschichtbildung von Zink unter atmosphärischen Bedingungen vorgestellt.
Der Vortrag berichtet über die Auslagerung von Standardproben nach DIN EN ISO 9223 bis 9226 aus Zink, Stahl, Kupfer und Aluminium auf den verschiedenen atmosphärischen Bewitterungsständen der Bundesanstalt für Materialforschung und -prüfung (BAM). Im Vortrag werden die Masseverluste, Korrosionsgeschwindigkeiten und Korrosivitätskategorien der Standardproben im freibewitterten und überdachten Bereich nach einem Jahr vorgestellt und Unterschiede hinsichtlich der Atmosphärenbedingungen aufgezeigt. Freibewitterte Proben zeigen dabei deutliche Unterschiede hinsichtlich ihres Korrosionsverhaltens im Vergleich zu überdachten Proben. Die ermittelten Korrosivitätskategorien sind sowohl standort- als auch materialspezifisch.
Ein neuer Ansatz bei elektrochemischen Korrosionsuntersuchungen kann durch den Einsatz von gelartigen Elektrolyten als Alternative zu wässrigen Prüfelektrolyten beschritten werden. Gelartige Elektrolyte ermöglichen minimalinvasive Untersuchungen an natürlich gebildeten Zinkdeckschichten. Dadurch können korrosionsrelevante Kennwerte ermittelt werden, die Aussagen zur Deckschichtbildung und zur Stabilität von atmosphärisch gebildeten Deckschichten erlauben. In diesem Beitrag wird anhand verschiedener Untersuchungen an Reinzink der Mehrwert von gelartigen Elektrolyten für die Korrosionsforschung und -prüfung verdeutlicht. Darüber hinaus werden neue Erkenntnisse zur Deckschichtbildung von Zink unter atmosphärischen Bedingungen vorgestellt.
Synthetic microswimmers mimicking biological movements at the microscale have been developed in recent years. Actuating helical magnetic materials with a homogeneous rotating magnetic field is one of the most widespread techniques for propulsion at the microscale, partly because the actuation strategy revolves around a simple linear relationship between the actuating field frequency and the propeller velocity.
However, full control of the swimmers’ motion has remained a challenge. Increasing the controllability of micropropellers is crucial to achieve complex actuation schemes that, in turn, are directly relevant for numerous applications. However, the simplicity of the linear relationship limits the possibilities and flexibilities of swarm control. Using a pool of randomly shaped magnetic microswimmers, we show that the complexity of shape can advantageously be translated into enhanced control. In particular, directional reversal of sorted micropropellers is controlled by the frequency of the actuating field. This directionality change is linked to the balance between magnetic and hydrodynamic forces. We further show an example of how this behavior can experimentally lead to simple and effective sorting of individual swimmers from a group. The ability of these propellers to reverse swimming direction solely by frequency increases the control possibilities and is an example for propeller designs, where the complexity needed for many applications is embedded directly in the propeller geometry rather than external factors such as actuation sequences.
A novel approach for the reconstruction of an equivalent volumetric heat source from a known weld pool shape is proposed. It is based on previously obtained weld pool geometries from a steady-state thermo-fluid dynamics simulation. Hereby the weld pool dimensions are obtained under consideration of the most crucial physical phenomena, such as phase transformations, thermo-capillary convection, natural convection and temperature-dependent material properties. The algorithm provides a time and calibration efficient way for the reproduction of the weld pool shape by local Lamé curves. By adjusting their parameters, the identification of the finite elements located within the weld pool is enabled. The heat input due to the equivalent heat source is assured by replacing the detected nodes’ temperature by the melting temperature.
The model offers variable parameters making it flexible and adaptable for a wide range of workpiece thicknesses and materials and allows for the investigation of transient thermal effects, e.g. the cooling stage of the workpiece. The calculation times remain acceptably short especially when compared to a fully coupled process simulation. The computational results are in good agreement with performed complete-penetration laser beam welding experiments.