نوع مقاله : مقاله پژوهشی
نویسندگان
ISFAHAN UNIVERSITY OF TECHNOLOGY
چکیده
جوشکاری اصطکاکی دورانی یکی از روشهای مهم اتصال قطعات مختلف جهت استفاده در صنایع پیشرفته به شمار می‌رود. با توجه به مشکلات اندازه‌گیری متغیرها در حین آزمون عملی و به منظور کاهش هزینه‌ها، استفاده از روشهای شبیهسازی عددی یک امکان بسیار موثر در تحقیقات علمی به شمار می‌رود. در این مقاله روش شبیهسازی عددی اجزای محدود برای شبیهسازی پیوسته مکانیکی-حرارتی و سپس معادلات مشخصه برای شبیهسازی ریزساختاری اتصال دو لوله مشابه از جنس آلیاژ اینکونل 718 به روش جوشکاری اصطکاکی دورانی مورد استفاده قرار گرفت. ابتدا با انجام شبیهسازی عددی مکانیکی-حرارتی پارامترهای مهم مؤثر بر تحولات متالورژیکی مثل توزیع دما، تنش و کرنش بدست آمد و سپس تحولات ریزساختاری مانند کسر حجمی تبلور مجدد و اندازه دانه ساختار نهایی محاسبه و به منظور صحت‌سنجی با نتایج آزمون عملی مقایسه شد. در شبیهسازی ریزساختاری با بهره‌گیری از الگوی جانسون-آورامی و زیرروال‌نویسی این الگو به زبان فرترن، خروجی‌‌های حاصل از حل مکانیکی-حرارتی به متغیرهای متالورژیکی تبدیل شدند. با استفاده از این الگو ضخامت ناحیه متأثر از تبلور مجدد برای مرکز و دیواره ضخامت لوله به ترتیب 480 و850 میکرومتر در شبیهسازی محاسبه شد. این مقادیر در آزمون عملی به ترتیب 500 و800 میکرومتر گزارش شدند. همچنین تغییرات اندازه دانه از مرکز لوله و مجاور فصل مشترک جوش تا دیواره لوله درشبیه‌سازی از 07/2 تا 15/2 میکرومتر پیش‌بینی شد که این روند در آزمون عملی از 9/1 تا 2/2 میکرومتر گزارش شده بود. نهایتاً در این مقاله تلاش شد تا با رسم منحنی‌های مختلف ارتباط بین متغیرهای مکانیکی-حرارتی و ریزساختاری بررسی و نتایج قابل انتظاری از توزیع متغیرهای ریزساختاری با تغییر متغیرهای مکانیکی-حرارتی حاصل گردد.
کلیدواژه‌ها
- جوشکاری اصطکاکی دورانی
- شبیهسازی اجزای محدود
- اینکونل718
- شبیهسازی ریزساختاری
- الگوی جانسون آورامی
- زیرروال‌نویسی
موضوعات
عنوان مقاله [English]
Thermomechanical and microstructural simulation of rotary friction welding process of Inconel718 alloy using the finite element method
نویسندگان [English]
- Aboozar Taherizadeh
- hossein. mani
- Mohammad Silani
ISFAHAN UNIVERSITY OF TECHNOLOGY
چکیده [English]
Rotary friction welding is one of the most important techniques for joining different parts in advanced industries.
Measuring the history of thermomechanical and microstructural parameters can be challenging and costly. To address these challenges, the finite element method was used to simulate thermomechanical and microstructural aspects of the welding of identical superalloy Inconel718 tubes. Therefore, in this research, thermomechanical and microstructural simulations were developed to calculate essential mechanical and metallurgical parameters such as temperature, strain, strain rate, volume fraction of dynamic recrystallization, and grain size distribution. Some of these parameters were then used to be verified with experimental test results. In the microstructural simulation, the Johnson-Avrami model was applied to convert thermomechanical parameters to metallurgical factors by using a FORTRAN subroutine. By employing the dynamic recrystallization kinetics model, the thickness of the recrystallization zone in the wall thickness was calculated to be 480 and 850 micrometers at the center and edge of the tube wall, respectively. These values were reported in the experimental measurements as 500 and 800 micrometers, respectively. Additionally, the grain size change from the center to the edge of the wall thickness, close to the weld interface, were predicted from 2.07 to 2.15 micrometers by simulations, which was comparable with the experimental measurements of 1.9 to 2.2 micrometers. Also, different types of curves were represented to investigate the correlation between thermomechanical and microstructural parameters. Predictable results were concluded from microstructure evolutions with changes by thermomechanical results.
کلیدواژه‌ها [English]
- Rotary friction welding
- Finite element method
- Inconel718
- Microstructural simulation
- Johnson-Avrami model
- subroutine
- Maalekian, M., “Friction Welding – Critical Assessment of Literature”, Science and Technology of Welding and Joining, 2007. 12(8): pp. 738-759.
- Yang, Y. C., Chen, W. L., and Lee, H. L., “A Nonlinear Inverse Problem in Estimating the Heat Generation in Rotary Friction Welding”, Numerical Heat Transfer, Part A: Applications, 2011. 59(2): pp. 130-149.
- Mousavi, S. and Kelishami, A. R., “Experimental and Numerical Analysis of the Friction Welding Process for the 4340 Steel and Mild Steel Combinations”, Welding Journal-New York-, 2008. 87(7): pp. 178.
- Li, W., Shi, S., Wang, F., Zhang, Z., Ma, T. and Li, J., “Numerical Simulation of Friction Welding Processes Based on ABAQUS Environment”, Journal of Engineering Science & Technology Review, Vol. 5, 2012.
- Fu, L., Duan, L., and Du, S., “Numerical Simulation of Inertia Friction Welding Process by Finite Element Method”, Welding Journal-New York, Vol. 82, pp. 65-S, 2003.
- Zhang, Q., Zhang, L., Liu, W., Zhang, X., Zhu, W., and Qu, S., “3D Rigid Viscoplastic FE Modelling of Continuous Drive Friction Welding Process”, Science and Technology of Welding and Joining, Vol. 11, pp. 737-743, 2006.
- Yang, X., Li, W., Fu, Y., Ye, Q., Xu, Y., Dong, X., Hu, K., Zou, Y., “Finite Element Modelling for Temperature, Stresses and Strains Calculation in Linear Friction Welding of TB9 Titanium Alloy”, Journal of Materials research and Technology, Vol. 8, pp. 4797-4818, 2019.
- Khosrowshahi, J. H., Sadeghi, M., and Rasti, A., “Numerical Simulation of Plastic Deformation in Direct-Drive Friction Welding of AISI 4140 and ASTM A106 Steel Tubes”, Archives of Civil and Mechanical Engineering, Vol. 20, pp. 1-13, 2020.
- Okeke, S. I., Harrison, N. M., and Tong, M., “Computational Modelling of Dynamic Recrystallisation of Ni-Based Superalloy During Linear Friction Welding”, The International Journal of Advanced Manufacturing Technology, pp. 1-24, 2022.
- Liu, F. and Nelson, T., “Grain Structure Evolution, Grain Boundary Sliding and Material Flow Resistance in Friction Welding of Alloy 718”, Materials Science and Engineering: A, Vol. 710, pp. 280-288, 2018.
- Dassault, “Systèmes (2020) Abaqus 2020 analysis user’s guide volume II: analysis”, Accessed 14th May 2020.
- Bennett, C., Hyde, T., and Williams, E., “Modelling and Simulation of the Inertia Friction Welding of Shafts”, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, Vol. 221, pp. 275-284, 2007.
- Jin, F., Li, J., Du, Y., Nan, X., Shi, J., Xiong, J., Zhang, F., “Numerical Simulation Based Upon Friction Coefficient Model on Thermo-Mechanical Coupling in Rotary Friction Welding Corresponding with Corona-Bond Evolution”, Journal of Manufacturing Processes, 45, pp. 595-602, 2019.
- Geng, P., Qin, G., and Zhou, J., “Numerical and Experimental Investigation on Friction Welding of Austenite Stainless Steel and Middle Carbon Steel”, Journal of Manufacturing Processes, Vol. 47, pp. 83-97, 2019.
- Saunders, N., Guo, Z., Miodownik, A., and Schillé, J. P., “Modelling High Temperature Mechanical Properties and Microstructure Evolution in Ni-Based Superalloys”, Sente, Softw, Intern, Rep., Vol. 9, 2008.
- Superalloys, O. N. B., “Modelling The Material Properties and Behaviour”.
- Guo, Z. L., Saunders, N., Miodownik, A. P., and Schille, J. P., “Quantification of High Temperature Strength of Nickel-Based Superalloys”, In Materials Science Forum, 2007, pp. 1319-1326.
- Clas, T. H., Ringius, “FE Modeling of Friction Welding Thermo-Mechanical Simulations Using Abaqus, in Department of Applied Mechanics”, Chalmers University of Technology, 2017.
- Wang, F., Li, W., Li, J., and Vairis, A., “Process Parameter Analysis of Inertia Friction Welding Nickel-Based Superalloy”, The International Journal of Advanced Manufacturing Technology, Vol. 71, pp. 1909-1918, 2014.
- Seli, H., Awang, M., Ismail, A. I. M., Rachman, E., and Ahmad, Z. A., “Evaluation of Properties and FEM Model of the Friction Welded Mild Steel-Al6061-Alumina”, Materials Research, Vol. 16, pp. 453-467, 2013.
- Uday, M., Ahmad Fauzi, M., Zuhailawati, H., and Ismail, A., “Advances in Friction Welding Process: A Review”, Science and technology of Welding and Joining, Vol. 15, pp. 534-558, 2010.
- Singh, S. K., Chattopadhyay, K., Phanikumar, G., and Dutta, P., “Experimental and Numerical Studies on Friction Welding of Thixocast A356 Aluminum Alloy”, Acta Materialia, Vol. 73, pp. 177-185, 2014.
- Bai, L., Wan, S., Yi, G., Shan, Y., Pham, S. T., Tieu, A. K.,Li, Y., Wang, R., “Temperature-Mediated Tribological Characteristics of 40CrNiMoA Steel and Inconel 718 Alloy During Sliding Against Si 3 N 4 Counterparts”, Friction, Vol. 9, pp. 1175-1197, 2021.
- Chen, L., Sun, W., Lin, J., Zhao, G., and Wang, G., “Modelling of Constitutive Relationship, Dynamic Recrystallization and Grain Size of 40Cr Steel During Hot Deformation Process”, Results in Physics, Vol. 12, pp. 784-792, 2019.
- Quan, G. Z., Mao, Y. P., Li, G. S., Lv, W. Q., Wang, Y., and Zhou, J., “A Characterization for the Dynamic Recrystallization Kinetics of As-Extruded 7075 Aluminum Alloy Based on True Stress–Strain Curves”, Computational Materials Science, Vol. 55, pp. 65-72, 2012.
- Yang, Q., Ji, C., and Zhu, M., “Modeling of the Dynamic Recrystallization Kinetics of A Continuous Casting Slab under Heavy Reduction”, Metallurgical and Materials Transactions A, Vol. 50, pp. 357-376, 2019.
- Li, C., Tan, Y., and Zhao, F., “Finite Element Simulation and Process Optimization of Microstructure Evolution in the Formation of Inconel 718 Alloy Bolts”, Materials Research Express, Vol. 6, pp. 026578, 2018.
- Razali, M. K., and Joun, M. S., “A New Approach of Predicting Dynamic Recrystallization Using Directly A Flow Stress Model and It's Application to Medium Mn Steel”, Journal of Materials Research and Technology, Vol. 11, pp. 1881-1894, 2021.
- Guo-Zheng, Q., “Characterization for Dynamic Recrystallization Kinetics Based on Stress-Strain Curves”, Recent developments in the study of recrystallization, pp. 61-64, 2013.
- Xu, Y., Chen, C., Zhang, X., Dai, H., Jia, J., and Bai, Z., “Dynamic Recrystallization Kinetics and Microstructure Evolution of An AZ91D Magnesium Alloy During Hot Compression”, Materials Characterization, Vol. 145, pp. 39-52, 2018.
- Humphreys, F. J. and Hatherly, M., “Recrystallization and Related Annealing Phenomena”,: elsevier, 2012.
- Lv, Y. P., Li, S. J., Zhang, X. Y., Li, Z. Y., and Zhou, K. C., “Modeling and Finite Element Analysis for the Dynamic Recrystallization Behavior of Ti-5Al-5Mo-5V-3Cr-1Zr Near β Titanium Alloy During Hot Deformation”, High Temperature Materials and Processes, Vol. 37, pp. 445-454, 2018.
- Lenard, J.G., Pietrzyk, M., and Cser, L., “Chapter 6 - Microstructure Evolution and Mechanical Properties of the Final Product, in Mathematical and Physical Simulation of the Properties of Hot Rolled Products, J.G. Lenard, M. Pietrzyk, and L. Cser, Editors. Elsevier Science Ltd: Oxford”, 151-236, 1999.
- My Nu, H. T., Minh, L. P., and Loc, N. H., “A Study on Rotary Friction Welding of Titanium Alloy (Ti6Al4V) ”, Advances in Materials Science and Engineering, Vol. 2019.
- Kessler, M., Hartl, R., Fuchs, A., and Zaeh, M., “Simulation of Rotary Friction Welding Using A Viscoelastic Maxwell Model”, Science and Technology of Welding and Joining, Vol. 26, pp. 68-74, 2021.
- Maalekian, M., and Cerjak, H., “Thermal-Phase Transformation Modelling and Neural Network Analysis of Friction Welding of Non-Circular Eutectoid Steel Components”, Welding in the World, Vol. 53, pp. R44-R51, 2009.
- Tang, T., Shi, Q., Lei, B., Zhou, J., Gao, Y., Li, Y.,Zhang, G., Chen, G., “Transition of Interfacial Friction Regime and Its Influence on Thermal Responses in Rotary Friction Welding of SUS304 Stainless Steel: A Fully Coupled Transient Thermomechanical Analysis”, Journal of Manufacturing Processes, Vol. 82, pp. 403-414, 2022.
- Damodaram, R., Raman, S. G. S., and Rao, K. P., “Microstructure and Mechanical Properties of Friction Welded Alloy 718”, Materials Science and Engineering: A, Vol. 560, pp. 781-786, 2013
)