Numerical modeling of the electron beam welding and its experimental validation

Electron Beam Welding (EBW) is a highly efficient and precise welding method increasingly used within the manufacturing chain and of growing importance in different industrial environments such as the aeronautical and aerospace sectors. This is because, compared to other welding processes, EBW induces lower distortions and residual stresses due to the lower and more focused heat input along the welding line. This work describes the formulation adopted for the numerical simulation of the EBW process as well as the experimental work carried out to calibrate and validate it. The numerical simulation of EBW involves the interaction of thermal, mechanical and metallurgical phenomena. For this reason, in this work the numerical framework couples the heat transfer process to the stress analysis to maximize accuracy. An in-house multi-physics FE software is used to deal with the numerical simulation. The definition of an ad hoc moving heat source is proposed to simulate the EB power surface distribution and the corresponding absorption within the work-piece thickness. Both heat conduction and heat radiation models are considered to dissipate the heat through the boundaries of the component. The material behavior is characterized by an apropos thermo-elasto-viscoplastic constitutive model. Titanium-alloy Ti6A14V is the target material of this work. From the experimental side, the EB welding machine, the vacuum chamber characteristics and the corresponding operative setting are detailed. Finally, the available facilities to record the temperature evolution at different thermo-couple locations as well as to measure both distortions and residual stresses are described. Numerical results are compared with the experimental evidence.Peer ReviewedPostprint (author's final draft

Grey-box Modelling of a Household Refrigeration Unit Using Time Series Data in Application to Demand Side Management

This paper describes the application of stochastic grey-box modeling to identify electrical power consumption-to-temperature models of a domestic freezer using experimental measurements. The models are formulated using stochastic differential equations (SDEs), estimated by maximum likelihood estimation (MLE), validated through the model residuals analysis and cross-validated to detect model over-fitting. A nonlinear model based on the reversed Carnot cycle is also presented and included in the modeling performance analysis. As an application of the models, we apply model predictive control (MPC) to shift the electricity consumption of a freezer in demand response experiments, thereby addressing the model selection problem also from the application point of view and showing in an experimental context the ability of MPC to exploit the freezer as a demand side resource (DSR).Comment: Submitted to Sustainable Energy Grids and Networks (SEGAN). Accepted for publicatio

Accurate prediction of melt pool shapes in laser powder bed fusion by the non-linear temperature equation including phase changes - isotropic versus anisotropic conductivity

In this contribution, we validate a physical model based on a transient temperature equation (including latent heat) w.r.t. the experimental set AMB2018-02 provided within the additive manufacturing benchmark series, established at the National Institute of Standards and Technology, USA. We aim at predicting the following quantities of interest: width, depth, and length of the melt pool by numerical simulation and report also on the obtainable numerical results of the cooling rate. We first assume the laser to posses a double ellipsoidal shape and demonstrate that a well calibrated, purely thermal model based on isotropic thermal conductivity is able to predict all the quantities of interest, up to a deviation of maximum 7.3\% from the experimentally measured values. However, it is interesting to observe that if we directly introduce, whenever available, the measured laser profile in the model (instead of the double ellipsoidal shape) the investigated model returns a deviation of 19.3\% from the experimental values. This motivates a model update by introducing anisotropic conductivity, which is intended to be a simplistic model for heat material convection inside the melt pool. Such an anisotropic model enables the prediction of all quantities of interest mentioned above with a maximum deviation from the experimental values of 6.5\%. We note that, although more predictive, the anisotropic model induces only a marginal increase in computational complexity

Thermal measurement and modeling of multi-die packages

Thermal measurement and modeling of multi-die packages became a hot topic recently in different fields like RAM chip packaging or LEDs / LED assemblies, resulting in vertical (stacked) and lateral arrangement. In our present study we show results for a mixed arrangement: an opto-coupler device has been investigated with 4 chips in lateral as well as vertical arrangement. In this paper we give an overview of measurement and modeling techniques and results for stacked and MCM structures, describe our present measurement results together with our structure function based methodology of validating the detailed model of the package being studied. Also, we show how to derive junction-to-pin thermal resistances with a technique using structure functions.Comment: Submitted on behalf of TIMA Editions (http://irevues.inist.fr/tima-editions

Adjustment of model parameters to estimate distribution transformers remaining lifespan

Currently, the electrical system in Argentina is working at its maximum capacity, decreasing the margin between the installed power and demanded consumption, and drastically reducing the service life of transformer substations due to overload (since the margin for summer peaks is small). The advent of the Smart Grids allows electricity distribution companies to apply data analysis techniques to manage resources more efficiently at different levels (avoiding damages, better contingency management, maintenance planning, etc.). The Smart Grids in Argentina progresses slowly due to the high costs involved. In this context, the estimation of the lifespan reduction of distribution transformers is a key tool to efficiently manage human and material resources, maximizing the lifetime of this equipment. Despite the current state of the smart grids, the electricity distribution companies can implement it using the available data. Thermal models provide guidelines for lifespan estimation, but the adjustment to particular conditions, brands, or material quality is done by adjusting parameters. In this work we propose a method to adjust the parameters of a thermal model using Genetic Algorithms, comparing the estimation values of top-oil temperature with measurements from 315 kVA distribution transformers, located in the province of Tucumán, Argentina. The results show that, despite limited data availability, the adjusted model is suitable to implement a transformer monitoring system.Fil: Jimenez, Victor Adrian. Universidad Tecnológica Nacional. Facultad Regional Tucumán. Centro de Investigación en Tecnologías Avanzadas de Tucumán; ArgentinaFil: Will, Adrian L. E.. Universidad Tecnológica Nacional. Facultad Regional Tucumán. Centro de Investigación en Tecnologías Avanzadas de Tucumán; ArgentinaFil: Gotay Sardiñas, Jorge. Universidad Tecnológica Nacional. Facultad Regional Tucumán. Centro de Investigación en Tecnologías Avanzadas de Tucumán; ArgentinaFil: Rodriguez, Sebastian Alberto. Universidad Tecnológica Nacional. Facultad Regional Tucumán. Centro de Investigación en Tecnologías Avanzadas de Tucumán; Argentina. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Tucumán; Argentin

Simulation support for performance assessment of building components

The determination of performance metrics for novel building components requires that the tests are conducted in the outdoor environment. It is usually difficult to do this when the components are located in a full-scale building because of the difficulty in controlling the experiments. Test cells allow the components to be tested in realistic, but controlled, conditions. High-quality outdoor experiments and identification analysis methods can be used to determine key parameters that quantify performance. This is important for achieving standardised metrics that characterise the building component of interest, whether it is a passive solar component such as a ventilated window, or an active component such as a hybrid photovoltaic module. However, such testing and analysis does not determine how the building component will perform when placed in a real building in a particular location and climate. For this, it is necessary to model the whole building with and without the building component of interest. A procedure has been developed, and applied within several major European projects, that consists of calibrating a simulation model with high-quality data from the outdoor tests and then applying scaling and replication to one or more buildings and locations to determine performance in practice of building components. This paper sets out the methodology that has been developed and applied in these European projects. A case study is included demonstrating its application to the performance evaluation of hybrid photovoltaic modules