Effects of laser beam energy on the pulsed Nd:YAG laser welding of thin sheet corrosion resistant materials

The aim of this study was to value the possibility to join, for pulsed Nd:YAG laser welding, thin foils lap joints for sealing components in corrosive environment. Experimental investigations were carried out using a pulsed neodymium: yttrium aluminum garnet laser weld to examine the influence of the pulse energy in the characteristics of the weld fillet. The pulse energy was varied from 1.0 to 2.5 J at increments of 0.25 J with a 4 ms pulse duration. The base materials used for this study were AISI 316L stainless steel and Ni-based alloys foils with 100 mu m thickness. The welds were analyzed by electronic and optical microscopy, tensile shear tests and micro hardness. The results indicate that pulse energy control is of considerable importance to thin foil weld quality because it can generate good mechanical properties and reduce discontinuities in weld joints. The ultimate tensile strength of the welded joints increased at first and then decreased as the pulse energy increased. In all the specimens, fracture occurred in the top foil heat-affected zone next to the fusion line. The microhardness was almost uniform across the parent metal, HAZ and weld metal. A slight increase in the fusion zone and heat-affected zone compared to those measured in the base metal was observed. This is related to the microstructural refinement in the fusion zone, induced by rapid cooling of the laser welding. The process appeared to be very sensitive to the gap between couples.

Strength of thin-walled elliptical cylinders supported at the minor axis

In this investigation it was found that the instability failure of curved sheet is nearly independent of the type of loading and is primarily a function of the maximum stress, radius-thickness ration and modulus of elasticity. A method of correlating the critical stress of thin sheet under several different types of loading is given. An explanation for the experimental critical stress of thin walled cylinders under bending being greater than that for pure compression is given. The strength of unstiffened thin walled circular nose sections under pure bending was found to be controlled by local instability of the section, rather than a large scale instability. The equation of local instability of curved sheet gives values which are in fair agreement with those found experimentally.

The strength of elliptical cylinders supported at the minor axis under bending plus shear loads is governed primarily by the bending strength, and is little effected by the sheer force unless the amount of shear is quite large with respect to the moment. The effect of increasing the amount of elliptically greatly reduces the bending and shear strength of nose sections. Under torsional loads the stress at buckling falls off as the ration of the major to minor axis increases but the failure stress decreases at a slower rate than the buckling stress. The length effect of semi-circular sections under torsion is similar to that of a circular tube, and can be obtained by Donnell's theoretical equation.

Mode I fracture of sheet metal

The perceived wisdom about thin sheet fracture is that (i) the crack propagates under mixed mode I & III giving rise to a slant through-thickness fracture profile and (ii) the fracture toughness remains constant at low thickness and eventually decreases with increasing thickness. In the present study, fracture tests performed on thin DENT plates of various thicknesses made of stainless steel, mild steel, 6082-O and NS4 aluminium alloys, brass, bronze, lead, and zinc systematically exhibit (i) mode I “bath-tub”, i.e. “cup & cup”, fracture profiles with limited shear lips and significant localized necking (more than 50% thickness reduction), (ii) a fracture toughness that linearly increases with increasing thickness (in the range of 0.5–5 mm). The different contributions to the work expended during fracture of these materials are separated based on dimensional considerations. The paper emphasises the two parts of the work spent in the fracture process zone: the necking work and the “fracture” work. Experiments show that, as expected, the work of necking per unit area linearly increases with thickness. For a typical thickness of 1 mm, both fracture and necking contributions have the same order of magnitude in most of the metals investigated. A model is developed in order to independently evaluate the work of necking, which successfully predicts the experimental values. Furthermore, it enables the fracture energy to be derived from tests performed with only one specimen thickness. In a second modelling step, the work of fracture is computed using an enhanced void growth model valid in the quasi plane stress regime. The fracture energy varies linearly with the yield stress and void spacing and is a strong function of the hardening exponent and initial void volume fraction. The coupling of the two models allows the relative contributions of necking versus fracture to be quantified with respect to (i) the two length scales involved in this problem, i.e. the void spacing and the plate thickness, and (ii) the flow properties of the material. Each term can dominate depending on the properties of the material which explains the different behaviours reported in the literature about thin plate fracture toughness and its dependence with thickness.

The effect of heat treatment on mechanical properties of pulsed Nd:YAG welded thin Ti6Al4V

Pulsed Nd:YAG has been adopted successfully in welding process of thin (0.7 mm) Ti6Al4V. Laser welding of such thin sheet requires a small focal spot, good laser beam quality and fast travel speed, since too much heat generation can cause distortion for thin sheet weld. The microstructures of Ti6Al4V were complex and strongly affected the mechanical properties. These structures include: a´ martensite, metastable ß, Widmanstätten, bimodal, lamellar and equiaxed microstructure. Bimodal and Widmanstätten structures exhibit a good-balance between strength and ductility. The microstructure of pulsed Nd:YAG welded Ti6Al4V was primarily a´ martensite, which showed the lowest ductility but not significantly high strength. A heat treatment at 950 followed by furnace cooling can transform the microstructure in the weld from a´ martensite structure into Widmanstätten structure.

Appraisal of open software for finite element simulation of 2D metal sheet laser cut.

FEA simulation of thermal metal cutting is central to interactive design and manufacturing. It is therefore relevant to assess the applicability of FEA open software to simulate 2D heat transfer in metal sheet laser cuts. Application of open source code (e.g. FreeFem++, FEniCS, MOOSE) makes possible additional scenarios (e.g. parallel, CUDA, etc.), with lower costs. However, a precise assessment is required on the scenarios in which open software can be a sound alternative to a commercial one. This article contributes in this regard, by presenting a comparison of the aforementioned freeware FEM software for the simulation of heat transfer in thin (i.e. 2D) sheets, subject to a gliding laser point source. We use the commercial ABAQUS software as the reference to compare such open software. A convective linear thin sheet heat transfer model, with and without material removal is used. This article does not intend a full design of computer experiments. Our partial assessment shows that the thin sheet approximation turns to be adequate in terms of the relative error for linear alumina sheets. Under mesh resolutions better than 10e−5 m , the open and reference software temperature differ in at most 1 % of the temperature prediction. Ongoing work includes adaptive re-meshing, nonlinearities, sheet stress analysis and Mach (also called ‘relativistic’) effects.

Stress concentration and load diffusion in rectangular panels with constant stress flanges

The stress concentration that occurs when load is diffused from a constant stress member into thin sheet is an important problem in the design of light weight structures. By using solutions in biharmonic polar-trigonometric series, the stress concentration can be effectively isolated so that highly accurate information necessary for design can be obtained. A method of analysis yielding high accuracy with limited effort is presented for rectangular panels with transverse edges free or supported by inextensional end ribs. Numerical data are given for panels with length twice the width.

A note on surface water waves for finite depth in the presence of an ice-cover

A class of I boundary value problems involving propagation of two-dimensional surface water waves, associated with water of uniform finite depth, against a plane vertical wave maker is investigated under the assumption that the surface is covered by a thin sheet of ice. It is assumed that the ice-cover behaves like a thin isotropic elastic plate. Then the problems under consideration lead to those of solving the two-dimensional Laplace equation in a semi-infinite strip, under Neumann boundary conditions on the vertical boundary as well as on one of the horizontal boundaries, representing the bottom of the fluid region, and a condition involving upto fifth order derivatives of the unknown function on the top horizontal ice-covered boundary, along with the two appropriate edge-conditions, at the ice-covered corner, ensuring the uniqueness of the solutions. The mixed boundary value problems are solved completely, by exploiting the regularity property of the Fourier cosine transform.

Pixel-level tunable liquid crystal lenses for auto-stereoscopic display

Mobile video and gaming are now widely used, and delivery of a glass-free 3D experience is of both research and development interest. The key drawbacks of a conventional 3D display based on a static lenticular lenslet array and parallax barriers are low resolution, limited viewing angle and reduced brightness, mainly because of the need of multiple-pixels for each object point. This study describes the concept and performance of pixel-level cylindrical liquid crystal (LC) lenses, which are designed to steer light to the left and right eye sequentially to form stereo parallax. The width of the LC lenses can be as small as 20-30 μm, so that the associated auto-stereoscopic display will have the same resolution as the 2D display panel in use. Such a thin sheet of tunable LC lens array can be applied directly on existing mobile displays, and can deliver 3D viewing experience while maintaining 2D viewing capability. Transparent electrodes were laser patterned to achieve the single pixel lens resolution, and a high birefringent LC material was used to realise a large diffraction angle for a wide field of view. Simulation was carried out to model the intensity profile at the viewing plane and optimise the lens array based on the measured LC phase profile. The measured viewing angle and intensity profile were compared with the simulation results. © 2014 SPIE.

Automated mixed dimensional modelling from 2D and 3D CAD models

The motivation for this paper is to present procedures for automatically creating idealised finite element models from the 3D CAD solid geometry of a component. The procedures produce an accurate and efficient analysis model with little effort on the part of the user. The technique is applicable to thin walled components with local complex features and automatically creates analysis models where 3D elements representing the complex regions in the component are embedded in an efficient shell mesh representing the mid-faces of the thin sheet regions. As the resulting models contain elements of more than one dimension, they are referred to as mixed dimensional models. Although these models are computationally more expensive than some of the idealisation techniques currently employed in industry, they do allow the structural behaviour of the model to be analysed more accurately, which is essential if appropriate design decisions are to be made. Also, using these procedures, analysis models can be created automatically whereas the current idealisation techniques are mostly manual, have long preparation times, and are based on engineering judgement. In the paper the idealisation approach is first applied to 2D models that are used to approximate axisymmetric components for analysis. For these models 2D elements representing the complex regions are embedded in a 1D mesh representing the midline of the cross section of the thin sheet regions. Also discussed is the coupling, which is necessary to link the elements of different dimensionality together. Analysis results from a 3D mixed dimensional model created using the techniques in this paper are compared to those from a stiffened shell model and a 3D solid model to demonstrate the improved accuracy of the new approach. At the end of the paper a quantitative analysis of the reduction in computational cost due to shell meshing thin sheet regions demonstrates that the reduction in degrees of freedom is proportional to the square of the aspect ratio of the region, and for long slender solids, the reduction can be proportional to the aspect ratio of the region if appropriate meshing algorithms are used.

Automatic decomposition and efficient semi-structured meshing of complex solids

In this paper, a novel approach to automatically sub-divide a complex geometry and apply an efficient mesh is presented. Following the identification and removal of thin-sheet regions from an arbitrary solid using the thick/thin decomposition approach developed by Robinson et al. [1], the technique here employs shape metrics generated using local sizing measures to identify long-slender regions within the thick body. A series of algorithms automatically partition the thick region into a non-manifold assembly of long-slender and complex sub-regions. A structured anisotropic mesh is applied to the thin-sheet and long-slender bodies, and the remaining complex bodies are filled with unstructured isotropic tetrahedra. The resulting semi-structured mesh possesses significantly fewer degrees of freedom than the equivalent unstructured mesh, demonstrating the effectiveness of the approach. The accuracy of the efficient meshes generated for a complex geometry is verified via a study that compares the results of a modal analysis with the results of an equivalent analysis on a dense tetrahedral mesh.

Creep and recovery of magnetorheological fluids: experiments and simulations

A direct comparative study on the creep-recovery behavior of conventional MR fluids is carried out using magnetorheometry and particle-level simulations. Two particle concentrations are investigated (ϕ=0.05 and 0.30) at two different magnetic field strengths (53 kA•m-1 and 173 kA•m-1) in order to match the yield stresses developed in both systems for easier comparison. Simulations are mostly started with random initial structures with some additional tests of using preassembled single chains in the low concentration case. Experimental and simulation data are in good qualitative agreement. The results demonstrate three regions in the creep curves: i) In the initial viscoelastic region, the chain-like (at ϕ=0.05) or percolated three-dimensional network (at ϕ=0.30) structures fill up the gap and the average cluster size remains constant; ii) Above a critical strain of 10 %, in the retardation region, these structures begin to break and rearrange under shear. At large enough imposed stress values, they transform into thin sheet-like or thick lamellar structures, depending on the particle concentration; iii) Finally in the case of larger strain values either the viscosity diverges (at low stress values) or reaches a constant low value (at high stress values), showing a clear bifurcation behavior. For stresses below the bifurcation point the MR fluid is capable to recover the strain by a certain fraction. However, no recovery is observed for large stress values.

When small is different: The case of membranes inside tubes

Recently, classical elasticity theory for thin sheets was used to demonstrate the existence of a universal structural behavior describing the confinement of sheets inside cylindrical tubes. However, this kind of formalism was derived to describe macroscopic systems. A natural question is whether this behavior still holds at nanoscale. In this work, we have investigated through molecular dynamics simulations the structural behavior of graphene and boron nitride single layers confined into nanotubes. Our results show that the class of universality observed at macroscale is no longer observed at nanoscale. The origin of this discrepancy is addressed in terms of the relative importance of forces and energies at macro and nano scales. © 2012 Materials Research Society.

Modelagem numérica da influência do eletrojato equatorial em dados magnetotelúricos produzidos por estruturas tridimensionais

A América do Sul apresenta várias peculiaridades geomagnéticas, uma delas, é a presença do Eletrojato Equatorial, o qual se estende de leste para oeste no Brasil ao longo de aproximadamente 3500 km. Considerando-se o fato de que a influência do Eletrojato Equatorial pode ser detectada a grandes distâncias do seu centro, isto suscita o interesse em se estudar os seus efeitos na exploração magnetotelúrica no Brasil. A influência do eletrojato equatorial na prospecção magnetotelúrica tem sido modelada para meios geológicos uni e bidimensionais valendo-se para isto de soluções analíticas fechadas e de técnicas numéricas tais como elementos finitos e diferenças finitas. Em relação aos meios geológicos tridimensionais, eles tem sido modelados na forma de "camadas finas", usando o algoritmo "thin sheet". As fontes indutoras utilizadas para simular o eletrojato equatorial nestes trabalhos, tem sido linhas de corrente, eletrojatos gaussianos e eletrojatos ondulantes. Por outro lado, o objetivo principal da nossa tese foi o modelamento dos efeitos que o eletrojato equatorial provoca em estruturas tridimensionais próprias da geofísica da prospecção. Com tal finalidade, utilizamos o esquema numérico da equação integral, com as fontes indutoras antes mencionadas. De maneira similar aos trabalhos anteriores, os nossos resultados mostram que a influência do eletrojato equatorial somente acontece em frequências menores que 10^-1 Hz. Este efeito decresce com a distância, mantendo-se até uns 3000 km do centro do eletrojato. Assim sendo, a presença de grandes picos nos perfis da resistividade aparente de um semi-espaço homogêneo, indica que a influência do eletrojato é notável neste tipo de meio. Estes picos se mostram com diferente magnitude para cada eletrojato simulado, sendo que a sua localização também muda de um eletrojato para outro. Entretanto, quando se utilizam modelos geo-elétricos unidimensionais mais de acordo com a realidade, tais como os meios estratificados, percebe-se que a resposta dos eletrojatos se amortece significativamente e não mostra muitas diferenças entre os diferentes tipos de eletrojato. Isto acontece por causa da dissipação da energia eletromagnética devido à presença da estratificação e de camadas condutivas. Dentro do intervalo de 3000 km, a resposta eletromagnética tridimensional pode ser deslocada para cima ou para baixo da resposta da onda plana, dependendo da localização do corpo, da frequência, do tipo de eletrojato e do meio geológico. Quando a resposta aparece deslocada para cima, existe um afastamento entre as sondagens uni e tridimensionais devidas ao eletrojato, assim como um alargamento da anomalia dos perfis que registra a presença da heterogeneidade tridimensional. Quando a resposta aparece deslocada para baixo, no entanto, há uma aproximação entre estes dois tipos de sondagens e um estreitamento da anomalia dos perfis. Por outro lado, a fase se mostra geralmente, de uma forma invertida em relação à resistividade aparente. Isto significa que quando uma sobe a outra desce, e vice-versa. Da mesma forma, comumente nas altas frequências as respostas uni e tridimensionais aparecem deslocadas, enquanto que nas baixas frequências se mostram com os mesmos valores, com exceção dos eletrojatos ondulantes com parâmetros de ondulação α = —2 e —3. Nossos resultados também mostram que características geométricas próprias das estruturas tridimensionais, tais como sua orientação em relação à direção do eletrojato e a dimensão da sua direção principal, afetam a resposta devido ao eletrojato em comparação com os resultados da onda plana. Desta forma, quando a estrutura tridimensional é rotacionada de 90°, em relação à direção do eletrojato e em torno do eixo z, existe uma troca de polarizações nas resistividades dos resultados, mas não existem mudanças nos valores da resistividade aparente no centro da estrutura. Ao redor da mesma, porém, se percebe facilmente alterações nos contornos dos mapas de resistividade aparente, ao serem comparadas com os mapas da estrutura na sua posição original. Isto se deve à persistência dos efeitos galvânicos no centro da estrutura e à presença de efeitos indutivos ao redor do corpo tridimensional. Ao alongar a direção principal da estrutura tridimensional, as sondagens magnetotelúricas vão se aproximando das sondagens das estruturas bidimensionais, principalmente na polarização XY. Mesmo assim, as respostas dos modelos testados estão muito longe de se considerar próximas das respostas de estruturas quase-bidimensionais. Porém, os efeitos do eletrojato em estruturas com direção principal alongada, são muito parecidos com aqueles presentes nas estruturas menores, considerando-se as diferenças entre as sondagens de ambos tipos de estruturas. Por outro lado, os mapas de resistividade aparente deste tipo de estrutura alongada, revelam um grande aumento nos extremos da estrutura, tanto para a onda plana como para o eletrojato. Este efeito é causado pelo acanalamento das correntes ao longo da direção principal da estrutura. O modelamento de estruturas geológicas da Bacia de Marajó confirma que os efeitos do eletrojato podem ser detetados em estruturas pequenas do tipo "horst" ou "graben", a grandes distâncias do centro do mesmo. Assim, os efeitos do eletrojato podem ser percebidos tanto nos meios estratificados como tridimensionais, em duas faixas de freqüência (nas proximidades de 10^-1 Hz e para freqüências menores que 10^-3 Hz), possivelmente influenciados pela presença do embasamento cristalino e a crosta inferior, respectivamente. Desta maneira, os resultados utilizando o eletrojato como fonte indutora, mostram que nas baixas freqüências as sondagens magnetotelúricas podem ser fortemente distorcidas, tanto pelos efeitos galvânicos da estrutura tridimensional como pela presença da influência do eletrojato. Conseqüêntemente, interpretações errôneas dos dados de campo podem ser cometidas, se não se corrigirem os efeitos do eletrojato equatorial ou, da mesma forma, não se utilisarem algoritmos tridimensionais para interpretar os dados, no lugar do usual modelo unidimensional de Tikhonov - Cagniard.