The development of a hot rolling process for variable cross-section I-beams

To meet targeted reductions in CO 2 emissions by 2050, demand for metal must be cut, for example through the use of lightweight technologies. However, the efficient production of weight optimized components often requires new, more flexible forming processes. In this paper, a novel hot rolling process is presented for forming I-beams with variable cross-section, which are lighter than prismatic alternatives. First, the new process concept is presented and described. A detailed computational and experimental analysis is then conducted into the capabilities of the process. Results show that the process is capable of producing defect free I-beams with variations in web depth of 30-50%. A full analysis of the process then indicates the likely failure modes, and identifies a safe operating window. Finally, the implications of these results for producing lightweight beams are discussed. © 2012 Elsevier B.V. All rights reserved.

An analytical model for guided wave inspection optimization for prismatic structures of any cross section.

This paper presents an analytical modeling technique for the simulation of long-range ultrasonic guided waves in structures. The model may be used to predict the displacement field in a prismatic structure arising from any excitation arrangement and may therefore be used as a tool to design new inspection systems. It is computationally efficient and relatively simple to implement, yet gives accuracy similar to finite element analysis and semi-analytical finite element analysis methods. The model has many potential applications; one example is the optimization of part-circumferential arrays where access to the full circumference of the pipe is restricted. The model has been successfully validated by comparison with finite element solutions. Experimental validation has also been carried out using an array of piezoelectric transducer elements to measure the displacement field arising from a single transducer element in an 88.9-mm-diameter pipe. Good agreement has been obtained between the two models and the experimental data.

Implementation of multi-group cross-section methodology in BGCore MC-depletion code

BGCore is a software package for comprehensive computer simulation of nuclear reactor systems and their fuel cycles. The BGCore interfaces Monte Carlo particles transport code MCNP4C with a SARAF module - an independently developed code for calculating in-core fuel composition and spent fuel emissions following discharge. In BGCore system, depletion coupling methodology is based on the multi-group approach that significantly reduces computation time and allows tracking of large number of nuclides during calculations. In this study, burnup calculation capabilities of BGCore system were validated against well established and verified, computer codes for thermal and fast spectrum lattices. Very good agreement in k eigenvalue and nuclide densities prediction was observed for all cases under consideration. In addition, decay heat prediction capabilities of the BGCore system were benchmarked against the most recent edition of ANS Standard methodology for UO2 fuel decay power prediction in LWRs. It was found that the difference between ANS standard data and that predicted by the BGCore does not exceed 5%.

The forming of variable cross-section I-beams by hot rolling

A process is presented for the forming of variable cross-section I-beams by hot rolling. Optimized I-beams with variable cross-section offer a significant weight advantage over prismatic beams. By tailoring the cross-section to the bending moment experienced within the beam, around 30% of the material can be saved compared to a standard section. Production of such beams by hot rolling would be advantageous, as It combines high volume capacity with high material yields. Through controlled variation of the roll gap during multiple passes, beams with a variable cross-section have been created using shaped rolls similar to those used for conventional I-beam rolling. The process was tested experimentally on a small scale rolling mill, using plasticine as the modelling material. These results were then compared to finite element simulations of individual stages of the process conducted using Abaqus/Standard. Results here show that the process can successfully form a beam with a variable depth web. The main failure modes of the process, and the limitations on the achievable variations In geometry are also presented. Finally, the question of whether or not optimal beam geometries can be created by this process Is discussed. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.

Experimental studies of the quench behaviour of MgB2 superconducting wires for fault current limiter applications

Various MgB2 wires with different sheath materials provided by Hyper Tech Research Inc., have been tested in the superconducting fault current limiter (SFCL) desktop tester at 24-26K in a self-field. Samples 1 and 2 are similarly fabricated monofilamentary MgB2 wires with a sheath of CuNi, except that sample 2 is doped with SiC and Mg addition. Sample 3 is a CuNi sheathed multifilamentary wire with Cu stabilization and Mg addition. All the samples with Nb barriers have the same diameter of 0.83mm and superconducting fractions ranging from 15% to 27% of the total cross section. They were heat-treated at temperatures of 700 °C for a hold time of 20-40min. Current limiting properties of MgB2 wires subjected to pulse overcurrents have been experimentally investigated in an AC environment in the self-field at 50Hz. The quench currents extracted from the pulse measurements were in a range of 200-328A for different samples, corresponding to an average engineering critical current density (Je) of around 4.8 × 10 4Acm-2 at 25K in the self-field, based on the 1νVcm-1 criterion. This work is intended to compare the quench behaviour in the Nb-barrier monofilamentary and multifilamentary MgB2 wires with CuNi and Cu/CuNi sheaths. The experimental results can be applied to the design of fault current limiter applications based on MgB2 wires. © IOP Publishing Ltd.

Calculating transport AC losses in stacks of high temperature superconductor coated conductors with magnetic substrates using FEM

In this paper, the authors investigate the electromagnetic properties of stacks of high temperature superconductor (HTS) coated conductors with a particular focus on calculating the total transport AC loss. The cross-section of superconducting cables and coils is often modeled as a two-dimensional stack of coated conductors, and these stacks can be used to estimate the AC loss of a practical device. This paper uses a symmetric two dimensional (2D) finite element model based on the H formulation, and a detailed investigation into the effects of a magnetic substrate on the transport AC loss of a stack is presented. The number of coated conductors in each stack is varied from 1 to 150, and three types of substrate are compared: non-magnetic weakly magnetic and strongly magnetic. The non-magnetic substrate model is comparable with results from existing models for the limiting cases of a single tape (Norris) and an infinite stack (Clem). The presence of a magnetic substrate increases the total AC loss of the stack, due to an increased localized magnetic flux density, and the stronger the magnetic material, the further the flux penetrates into the stack overall. The AC loss is calculated for certain tapes within the stack, and the differences and similarities between the losses throughout the stack are explained using the magnetic flux penetration and current density distributions in those tapes. The ferromagnetic loss of the substrate itself is found to be negligible in most cases, except for small magnitudes of current. Applying these findings to practical applications, where AC transport current is involved, superconducting coils should be wound where possible using coated conductors with a non-magnetic substrate to reduce the total AC loss in the coil. © 2011 Elsevier B.V. All rights reserved.