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At least 865 records · Page 48

Determining Sizes of Particles in a Flow from DPIV Data

A proposed method of measuring the size of particles entrained in a flow of a liquid or gas would involve utilization of data from digital particle-image velocimetry (DPIV) of the flow. That is to say, with proper design and operation of a DPIV system, the DPIV data could be processed according to the proposed method to obtain particle sizes in addition to particle velocities. As an additional benefit, one could then compute the mass flux of the entrained particles from the particle sizes and velocities. As in DPIV as practiced heretofore, a pulsed laser beam would be formed into a thin sheet to illuminate a plane of interest in a flow field and the illuminated plane would be observed by means of a charge-coupled device (CCD) camera aimed along a line perpendicular to the illuminated plane. Unlike in DPIV as practiced heretofore, care would be taken to polarize the laser beam so that its electric field would lie in the illuminated plane, for the reason explained in the next paragraph. The proposed method applies, more specifically, to transparent or semitransparent spherical particles that have an index of refraction different from that of the fluid in which they are entrained. The method is based on the established Mie theory, which describes the scattering of light by diffraction, refraction, and specular reflection of light by such particles. In the case of a particle illuminated by polarized light and observed in the arrangement described in the preceding paragraph, the Mie theory shows that the image of the particle on the focal plane of the CCD camera includes two glare spots: one attributable to light reflected toward the camera and one attributable to light refracted toward the camera. The distance between the glare spots is a known function of the size of the particle, the indices of refraction of the particle material, and design parameters of the camera optics. Hence, the size of a particle can be determined from the distance between the glare spots. The proposed method would be implemented in an algorithm that would automatically identify, and measure the distance between, the glare spots for each particle for which a suitable image has been captured in a DPIV image frame. The algorithm (see figure) would begin with thresholding of data from the entire image frame to reduce noise, thereby facilitating discrimination of particle images from the background and aiding in the separation of overlapping particles. It is important not to pick a threshold level so high that the light intensity between a given pair of glare spots does not fall below the threshold value, leaving the glare spots disconnected. The image would then be scanned in a sequence of rows and columns of pixels to identify groups of adjacent pixels that contain nonzero brightnesses and that are surrounded by pixels of zero brightness. Each such group would be assumed to constitute the image of one particle. Each such group would be further analyzed to determine whether the image was saturated; saturated particle images must be rejected because the locations of glare spots in saturated images cannot accurately be determined. Within each unsaturated particle image, the centroids (deemed to be the locations) of the glare spots would be determined by means of gradients of brightness distributions and three-point horizontal and three-point vertical Gaussian estimates based on the brightness values of the brightest pixels and the pixels adjacent to them. If the brightness of a given particle image contained only one peak, then it would be assumed that a second glare spot did not exist and that image would be rejected.

Wernet, M. P.↗

Resolving local structural motifs across the phase evolution of zinc titanates with computational x-ray absorption spectroscopy

Resolving the local structure motifs that characterize phase evolution as a function of composition is a key challenge in structure characterization of complex materials. Here, in this study, we combine first-principles simulations and x-ray absorption near-edge structures (XANES) analysis to gain insights into the structure evolution revealed by measurements across a combinatorial zinc titanate thin film, which was grown with smoothly varying composition over a wide range of the Ti:Zn ratio. Specifically, we propose a cluster blind-signal-separation (cBSS) method for XANES spectral analysis based on a library of the structures and spectra of representative local motifs. In addition to motifs from zinc titanate crystals, two types of Ti-defect models constructed in this study are key to the understanding of the structure characteristics in the Zn-rich region. The cBSS method makes use of both spectral clustering of the simulated site-XANES spectra library and the BSS procedure to construct high-fidelity spectral basis functions from an experimental spectral sequence. The method provides a rigorous measure of the spectral sensitivity and basis completeness. The results of the XANES analysis are corroborated with other experimental modalities, including x-ray diffraction and spectroscopic ellipsometry, to validate the cBSS method. The calculated motif weights resulting from fitting the XANES spectra with the cBSS basis probe the atomic structure characteristics of both crystalline and amorphous phases as a function of the Ti/Zn composition. The insights of the local structure motif evolution are pivotal to the understanding of the nonmonotonic trend in the optical gap, which may lead to potential applications through tuning the optical properties of zinc titanate. The workflow of the XANES spectral analysis developed in this work can be generalized to construct the structure-property relationship in a broad material space.

36 MATERIALS SCIENCE↗

Interference from the Deep Space Network's 70-m High Power Transmitter in Goldstone, CA to 3G Mobile Users Operating in the Surrounding Area

The International Telecommunications Union (ITU) has allocated 2110-2200 MHz for the third generation (3G) mobile services. Part of the spectrum (2110-2120 MHz) is allocated for space research service and has been used by the DSN for years for sending command uplinks to deep space missions. Due to the extremely high power transmitted, potential interference to 3G users in areas surrounding DSN Goldstone exists. To address this issue, a preliminary analytical study has been performed and computer models have been developed. The goal is to provide theoretical foundation and tools to estimate the strength of interference as a function of distance from the transmitter for various interference mechanisms, (or propagation modes), and then determine the size of the area in which 3G users are susceptible to interference from the 400-kW transmitter in Goldstone. The focus is non-line-of-sight interference, taking into account of terrain shielding, anomalous propagation mechanisms, and technical and operational characteristics of the DSN and the 3G services.

propagation↗

Computational thermodynamics-guided alloy design and phase stability in CoCrFeMnNi-based medium-and high-entropy alloys: An experimental-theoretical study

A computational thermodynamics approach has been employed to design CoCrFeMnNi-based medium- and high-entropy alloys (M/HEAs) with systematically varied compositions (Co(( 80-X )/ 2 )Cr(( 80-X )/ 2 )Fe X Mn 10 Ni 10 with x = 30, 40, and 50 at.%) and phase stability. Since the formation of sigma phase, usually brittle and undesirable, is a common concern, when this class of alloys is subjected to elevated temperatures (600–1000 °C), predicting its formation becomes essential. Thus, its formation and the phase equilibria were studied using the CALPHAD method, and two empirical methods, namely, valence electron concentration (VEC) and paired sigma-forming element (PSFE). Isothermal aging treatments at 900–1100 °C for 20 h were performed, since CALPHAD and VEC/PSFE predictions diverged. Both prediction methods were compared with experimental characterization by a combination of scanning electron microscopy and high-energy synchrotron X-ray diffraction. In conclusion, the predictions from the VEC/PSFE and CALPHAD calculations (depending on the database used) were shown to be quite accurate.

36 MATERIALS SCIENCE↗

Fatigue performance of laser powder bed fusion hydride-dehydride Ti-6Al-4V powder

We report hydride-dehydride (HDH) Ti-6Al-4V alloy with particle size distribution of 50–120 µm is laser powder bed fusion (L-PBF) processed using optimum processing parameters and a near-fully dense structure with a density of 99.9 % is achieved. Microstructural observations and phase analyses indicate formation of columnar β grains with acicular α/α' phases in as-built condition. The roughness of the as-fabricated samples is significant with an average roughness of R a = 15.71 ± 3.96 µm and a root mean square roughness of R rms = 108.4 ± 24.9 µm, however, both values are reduced to R a = 0.19 ± 0.04 µm and R rms = 4.9 ± 0.6 µm after mechanical grinding. Mechanical tests are carried out on as-fabricated specimens followed by stress relief treatment. All samples are tested to failure in fatigue, under fully-reversed tension-compression conditions of R = –1. The as-built samples failed from the surface with crack initiation mainly at micro-notches, whereas after mechanically grinding, crack initiation changed to subsurface defects such as pores. Minimizing surface roughness by mechanically grinding eliminates surface micro-notches which improves fatigue strength in the high cycle fatigue region. Fatigue notch factor calculations showed that the effect of surface roughness was significantly lower when HDH powder is used compared to standard spherical powder. X-ray diffraction analysis revealed an in-plane compressive stress, micro-strain and grain refinement on the surface of the mechanically ground samples. Fractography observations (macroscale) revealed a fully brittle fracture in the first stage of crack growth with a transition to a dominantly ductile fracture in the third stage of crack growth. On the other hand, at the micro scale, even the brittle fracture regions showed evidence of ductile fracture within the α' martensite laths.

36 MATERIALS SCIENCE↗

Gluon Sivers function from forward exclusive χ c 1 photoproduction on unpolarized protons

Exclusive production of a χ c 1 axial vector quarkonia in photon-proton scattering at high energies requires a C -odd t -channel exchange. In the limit of vanishing momentum transfer this occurs either via the exchange of a photon, the Primakoff process, where the spin of the proton does not change. For axial-vector meson production, as a consequence of the Landau-Yang theorem, the Primakoff cross section is finite as t → 0 . Alternatively, a C -odd spin dependent Odderon can be exchanged, which involves a spin flip of the proton. The resulting cross section is related to the square of the collinear trigluon correlator or the k ⊥ -moment of the gluon Sivers function. Using two models for the gluon Sivers function from the literature we compute the ratio of Sivers to Primakoff cross sections and the angular coefficient λ θ governing the angular distribution of the χ c 1 → J / ψ + γ decay as functions of x . We point out that these observables constrain the magnitude of the gluon Sivers function at small x which could be accessed in electron-proton scattering and ultraperipheral proton-proton and nucleus-proton collisions. Published by the American Physical Society 2025

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Efficiency measurements of reflection gratings in the 100-300-A band

Zero-order and first-order efficiencies of plane diffraction grazings over the 100-300-A band have been measured using the NRL beamline facility at the National Synchrotron Light Source. Measurements were taken at grating angles of 5, 10, and 15 deg, and the incident radiation was polarized primarily in the transverse magnetic mode. Four (three laminar, one blazed) of the gratings were ion etched in high quality quartz blanks, overcoated with 200 A of gold. A fifth (blazed) grating was ruled in gold. The line densities are 1000, 2000, and 3600 grooves/mm for those with laminar profiles. Both blazed gratings have a blaze angle of 8 deg and line densities of 3600 grooves/mm. Measured first-order efficiencies up to 15 percent were obtained for the laminar gratings and up to 8 percent was obtained for the ion-etched blazed grating. Much lower efficiencies (not greater than 2 percent) were measured for the ruled grating. A computer program was written to calculate grating efficiencies using a full electromagnetic model. Measured efficiencies of the ion-etched gratings agree well with predicted values, but the measured first-order efficiency of the ruled grating is much lower than predicted.

Meekins, John F.↗

The structure, composition, and performance impact of a YSZ-GDC interdiffusion layer in solid oxide electrolysis cells

This study provides a combined experimental and computational investigation into the structure and impact of the cation interdiffusion layer that appears at the gadolinium doped ceria (GDC)/yttria stabilized zirconia (YSZ) interface in solid oxide electrolysis cells (SOECs). Scanning transmission electron microscopy (STEM) illustrates that a ∼0.4 μm interdiffusion layer (IDL) with an intermixed cation distribution and fine grain size forms upon sintering. STEM identifies that the interdiffusion layer exists in the cubic fluorite structure despite changes in cation composition. The interdiffusion layer microstructure formed during sintering does not change during SOEC testing at either 1.3V or heightened voltage pulse testing. Modeling predicts that ionic conductivity may decrease in the interdiffusion layer due to Coulombic trapping between mobile oxygen vacancies and excess Gd 3+ acceptor dopants. Yet, the density and continuous nature of the layer should benefit cell stability by substantially reducing the formation of SrZrO 3 , which is corroborated by STEM and Synchrotron X-ray diffraction (XRD). We conclude that the interdiffusion layer acts as a beneficial barrier to Sr diffusion, when operating in a regime where electrolyte void formation is not observed.

organic↗

High-Pressure Synthesis of Bulk Cobalt Cementite, Co 3 C

Transition metal carbides find use in a wide range of advanced high-resilience applications including high-strength steels, heat shields, and deep-earth drills. However, carbides of the mid-to-late transition metals remain difficult to isolate and characterize on account of their metastability, which precludes the preparation of high-quality bulk single crystal samples using traditional solid-state methods. Herein, we report a combined computational and experimental survey of the cobalt-carbon binary system under high pressures and demonstrate that pressure offers a route toward the bulk synthesis of the metastable cementite-type cobalt carbide, Co 3 C, which under ambient conditions can only be prepared in low-dimensional thin film or nanoparticle forms. First-principles calculations reveal two competitive low-energy stoichiometric phases under ambient pressures - Pnnm-Co 2 C (Fe 2 C-type) and Pnma-Co 3 C (Fe 3 Ctype) - consistent with the known low-dimensional phases that have been studied for their promising magnetic properties. However, the calculated formation enthalpy of Pnma-Co 3 C decreases steadily with the applied pressure, while that of Pnnm-Co 2 C increases. Here, we pursue these results using high-pressure laser-heated synthesis methods coupled with in situ X-ray diffraction and observe the formation of Pnma-Co 3 C above 4.8 GPa. We determine the experimental bulk modulus of Co 3 C to be K o = 237 GPa (K p = 4.0). First-principles calculations of the phonon modes in Co 3 C reveal dynamical instabilities at ambient pressure that are absent under compression. These results offer a promising new route for the synthesis of rare-earth-free magnets.

36 MATERIALS SCIENCE↗

Preventing native oxide formation in niobium thin films through platinum encapsulation

Superconducting transmon qubits are a key technology in quantum computing, with niobium (Nb) widely used due to its favorable superconducting properties and compatibility with scalable fabrication. However, the performance of Nb-based qubits is hindered by two-level systems (TLS), which arise predominantly from native oxide layers at surfaces and interfaces. These oxides and suboxides form rapidly in air and contribute significantly to decoherence by introducing dielectric losses. While various mitigation strategies, including thermal-annealing, chemical-etching, and nitrogen plasma treatment, have been explored, many are challenging to integrate into large-scale manufacturing due to complexity and instability in ambient conditions. In this study, we investigate the structural, chemical, and superconducting properties of room-temperature sputtered Nb thin films grown on sapphire substrates. We focus on a surface protection strategy using noble metal encapsulation with platinum (Pt) to suppress oxides and reduce TLS-related losses. Structural and chemical characterization were performed using X-ray diffraction, X-ray photoelectron spectroscopy, and transmission electron microscopy. Superconducting properties were measured using a physical property measurement system. Results demonstrate that Pt encapsulation effectively suppresses surface oxidation and mitigates its detrimental impact on superconducting performance. In conclusion, this approach offers a promising path toward enhancing the coherence of Nb-based qubits while remaining compatible with scalable-fabrication processes.

36 MATERIALS SCIENCE↗

Molecular chemisorption of N 2 on IrO 2 (110)

We investigated the adsorption of N 2 on stoichiometric and O-rich IrO 2 (110) surfaces using temperature programmed desorption (TPD) experiments and density functional theory (DFT) calculations. TPD shows that N 2 desorbs predominantly from the stoichiometric-IrO 2 (110) surface in a well-defined peak at 270 K for N 2 coverages below about 0.5 ML, and that a shoulder centered near 235 K develops in the N 2 TPD traces as the coverage approaches saturation, indicating that adsorbed N 2 molecules become destabilized at high N 2 coverage. Experiments of N 2 adsorption onto O-rich IrO 2 (110) surfaces provide evidence that N 2 adsorbs exclusively on the coordinatively-unsaturated Ir atoms (Ircus) of the surface, and that pre-adsorbed O-atoms (“on-top” oxygen) stabilize adsorbed N 2 molecules, causing the main N 2 TPD peak to shift toward higher temperature with increasing oxygen coverage. Consistent with prior results, our DFT calculations predict that an N 2 molecule preferentially adsorbs into an upright configuration on an Ircus atom of the IrO 2 (110) surface and achieves a binding energy of about 100 kJ/mol. The computed binding energy agrees well with our experimental estimate of ~90 kJ/mol for low N 2 coverages on stoichiometric IrO 2 (110). Lastly, the DFT calculations also quantitatively reproduce the observed stabilization of N 2 by co-adsorbed on-top O-atoms and predict the destabilization of N 2 on IrO 2 (110) as the N 2 adlayer becomes crowded at high coverage.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Probing the thermal decomposition of plutonium (III) oxalate with IR and Raman spectroscopy, X-ray diffraction, and electron microscopy

The thermal decomposition of Pu(III) oxalate was analyzed by Raman microspectroscopy, infrared spectroscopy, scanning electron microscopy, and powder X-ray diffraction. These data show that crystalline Pu 2 (C 2 O 4 ) 3 •9H 2 O progressively loses water and oxalate ligands as it is heated, which leads to a decrease in long-range lattice ordering, though minimal changes are observed in gross crystalline morphology. The onset of PuO 2 formation was observed between 200 - 250 °C. Thermal decomposition of oxalate ligands leads to the formation of CO 2 and plutonium oxalate-carbonate moieties, which had not been observed in previously published thermogravimetric measurements of Pu(III) oxalate. Formation of plutonium oxalate-carbonate moieties is believed to be associated with a change in the plutonium oxidation state from 3+ to 4+, which occurs prior to PuO 2 formation. The data provided herein demonstrate the rich spectroscopic nature of a rather underexplored, and technologically relevant, plutonium system. Ideally these results will further future investigations into the Pu(III) oxalate system both experimentally and computationally.

36 MATERIALS SCIENCE↗

Soft-mode enhanced type-I superconductivity in LiPd 2 Ge

The synthesis, crystal structure, and physical properties (magnetization, resistivity, heat capacity) in combination with theoretical calculations of the electronic structure and phonon properties are reported for intermetallic compounds LiPd 2 X ( X = Si, Ge, and Sn). LeBail refinement of powder x-ray diffraction data confirms that all compounds belong to the Heusler family (space group $\textit{F m-3m}$, No. 225). The lattice parameter increases with atomic size of X , and its value varies from $\textit{a}$ = 5.9059(4) Å for LiPd 2 Si and $\textit{a}$ = 6.0082(3)Å for LiPd 2 Ge, to $\textit{a}$ = 6.2644(1) Å for LiPd 2 Sn. The first compound, LiPd 2 Si, has apparently not been previously reported. All measured quantities demonstrate that LiPd 2 Ge exhibits superconductivity below $T_c$ = 1.96 K and the normal- and superconducting-state data indicate that it is a weak-strength type-I superconductor ($C/γT_c$ = 1.38) with electron-phonon coupling constant $λ_{e–p}$ = (0.53–0.56). LiPd 2 Si and LiPd 2 Sn are not superconducting above 1.68 K. The experimental observations are supported by theoretical calculations which show that LiPd 2 Ge has the highest computed $λ_{e–p}$ and $T_c$ of the group. A strong softening of the acoustic phonon mode is calculated, and in the case of X = Ge and Sn, imaginary phonon frequencies were computed. In this work, the soft mode is most pronounced in the case of LiPd 2 Ge, which suggests its correlation with superconductivity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

High-Throughput Electric-Field-Assisted Sintering and Characterization Techniques for Materials Discovery

Despite improvements in computing and modeling capabilities, the performance of new materials, particularly those which deviate greatly in composition from well-studied materials (e.g., high-entropy alloys), can be difficult to simulate given the lack of available experimental property data. While some modeling techniques may attempt to predict the properties of these exotic materials, most are forced to make extrapolations from more traditional materials. To fulfill the need for accelerated material synthesis and property measurement, a high-throughput methodology has been developed. Utilizing electric-field-assisted sintering (EFAS), also known as spark plasma sintering (SPS), equipped with custom tooling, samples of differing alloy compositions can be produced simultaneously as a single alloy array. Several arrays have been produced with compositions spanning the Co-Cr-Fe-Mn-Ni alloy family, including many high-entropy alloys, while the novel array geometry has enabled the samples to be polished and characterized in parallel, using X-ray diffraction, scanning-electron microscopy, and laser-based thermal diffusivity measurements.

36 MATERIALS SCIENCE↗

Interlayer spacing in pillared and grafted MCM-22 type silicas: density functional theory analysis versus experiment

Pillaring of synthetic layered crystalline silicates and aluminosilicates provides a strategy to enhance their adsorption and separation performance, and can facilitate the understanding of such behavior in more complex natural clays. In this study, we perform the first-principles density functional theory calculations for the pillaring of the pure silica polymorph of an MCM-22 type molecular sieve. Starting with a precursor material MCM-22P with fully hydroxylated layers, a pillaring agent, (EtO) 3 SiR, can react with hydroxyl groups (–OH) on adjacent internal surfaces, 2(–OH) + (EtO) 3 SiR + H 2 O → (–O) 2 SiOHR + 3EtOH, to form a pillar bridging these surfaces, or with a single hydroxyl, –OH + (EtO) 3 SiR + 2H 2 O → (–O)Si(OH) 2 R + 3EtOH, grafting to one surface. For computational efficiency, we replace the experimental organic ligand, R, by a methyl group. We find that the interlayer spacing in MCM-22 is reduced by 2.66 Å relative to weakly bound layers in the precursor MCM-22P. Including (–O) 2 SiR bridges for 50% (100%) of the hydroxyl sites in MCM-22P increases the interlayer spacing relative to MCM-22 by 2.52 Å (2.46 Å). For comparison, we also analyze the system where all –OH groups in MCM-22P are replaced by non-bridging grafted (–O)Si(OH) 2 R which results in a smaller interlayer spacing expansion of 2.17 Å relative to MCM-22. Our results for the interlayer spacing in the pillared materials are compatible with experimental observations for a similar MCM-22 type material with low Al content (Si : Al = 51 : 1) of an expansion relative to MCM-22 of roughly 2.8 Å and 2.5 Å from our x-ray diffraction and scanning transmission electron microscopy analyses, respectively. The latter analysis reveals significant variation in individual layer spacings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Toward fully automated UED operation using two-stage machine learning model

To demonstrate the feasibility of automating UED operation and diagnosing the machine performance in real time, a two-stage machine learning (ML) model based on self-consistent start-to-end simulations has been implemented. This model will not only provide the machine parameters with adequate precision, toward the full automation of the UED instrument, but also make real-time electron beam information available as single-shot nondestructive diagnostics. Furthermore, based on a deep understanding of the root connection between the electron beam properties and the features of Bragg-diffraction patterns, we have applied the hidden symmetry as model constraints, successfully improving the accuracy of energy spread prediction by a factor of five and making the beam divergence prediction two times faster. The capability enabled by the global optimization via ML provides us with better opportunities for discoveries using near-parallel, bright, and ultrafast electron beams for single-shot imaging. It also enables directly visualizing the dynamics of defects and nanostructured materials, which is impossible using present electron-beam technologies.

36 MATERIALS SCIENCE↗

High-Pressure Effects on an Octa-Hydrated Curium Complex: An Experimental and Theoretical Investigation

An octa-hydrated curium compound [Cm(H 2 O) 8 ](Hdtp)(dtp)·H 2 O (Cm1,H 2 dtp = 2,3-di(tetrazol-5-yl)pyrazine) along with its lanthanide analogues [Ln(H 2 O) 8 ](Hdtp)-(dtp)·H 2 O (Ln1, Ln 3+ = La 3+ –Nd 3+ , Sm 3+ –Lu 3+ ) were synthesized and characterized using single crystal X-ray diffraction and spectroscopic methods. Bond length analysis of VIII Cm(III)–OH 2 (where VIII refers to the coordination number) was compared to VIII Ln(III)–OH 2 (Ln 3+ = Nd 3+ and Sm 3+ ), indicating similar VIII M(III)–OH 2 bond lengths owing to the similar eight-coordinate ionic radii of these VIII M(III) cations. Owing to the reduced coordination number, the VIII Cm(III)–OH 2 bond lengths were shorter than previously reported IX Cm(III)–OH 2 bonds in [Cm(H 2 O) 9 ](CF 3 SO 3 ) 3 . The octa-aquo complexes were also characterized by solid-state UV–vis–NIR spectroscopy in addition to variable-temperature and variable-pressure photoluminescence. Variable-pressure absorption spectra of Cm1 were compared with Ln1 and show that the Cm(III) f → f transitions have a stronger dependence on pressure than that observed in Ln1 (Ln 3+ = Nd 3+ and Sm 3+ ). The experimental and computational analyses reveal that the monotonic decrease in the computed energy difference between the ground state and the first excited state corresponds to the observed red shift of the photoluminescence peak. This is accompanied by a gradual reduction in the average Cm(III)–OH 2 bond length and a delocalization of spin densities, alongside an intensified interaction involving the 5f orbitals under increasing pressure. Furthermore, these changes accommodate the new geometry and collectively modify the energy landscape, resulting in peak broadening and quenching.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Adaptively remeshed multiphysical modeling of resistance forge welding with experimental validation of residual stress fields and measurement processes

Welding processes used in the production of pressure vessels impart residual stresses in the manufactured component. Computational modeling is critical to predicting these residual stress fields and understanding how they interact with notches and flaws to impact pressure vessel durability. Here, in this work, we present a finite element model for a resistance forge weld and validate it using laboratory measurements. Extensive microstructural changes, near-melt temperatures, and large localized deformations along the weld interface pose significant challenges to Lagrangian finite element modeling. The proposed modeling approach overcomes these roadblocks in order to provide a high-fidelity simulation that can predict the residual stress state in the manufactured pressure vessel; a rich microstructural constitutive model accounts for material recrystallization dynamics, a frictional-to-tied contact model is coordinated with the constitutive model to represent interfacial bonding, and adaptive remeshing is employed to alleviate severe mesh distortion. An interrupted-weld approach is applied to the simulation to facilitate comparison to displacement measures. Several techniques are employed for residual stress measurement in order to validate the finite element model: neutron diffraction, the contour method, and the slitting method. Model-measurement comparisons are supplemented with detailed simulations that reflect the configurations of the residual-stress measurement processes themselves. The model results show general agreement with experimental measurements, and we observe some similarities in the features around the weld region. Factors that contribute to model-measurement differences are identified. Finally, we conclude with some discussion of the model development and residual stress measurement strategies, including how to best leverage the efforts put forth here for other weld problems.

36 MATERIALS SCIENCE↗