Modelling and visualisation of material flow in friction stir spot welding

The material flow in friction stir spot welding of aluminium to both aluminium and steel has been investigated, using pinless tools in a lap joint geometry. The flow behaviour was revealed experimentally using dissimilar Al alloys of similar strength. The effect on the material flow of tool surface features, welding conditions (rotation speed, plunge depth, dwell time), and the surface state of the steel sheet (un-coated or galvanized) have been systematically studied. A novel kinematic flow model is presented, which successfully predicts the observed layering of the dissimilar Al alloys under a range of conditions. The model and the experimental observations provide a consistent interpretation of the stick-slip conditions at the tool-workpiece interface, addressing an elusive and long-standing issue in the modelling of heat generation in friction stir processing.The authors wish to thank the EPSRC for funding this research through the following grants: Friction Joining – Low Energy Manufacturing for Hybrid Structures in Fuel Efficient Transport Applications (EP/G022402/1 and EP/G022674/1); and LATEST2, Light Alloys Towards Environmentally Sustainable Transport (EP/H020047/1).This is the author accepted manuscript. The final version is available from Elsevier at http://dx.doi.org/10.1016/j.jmatprotec.2015.06.02

On the analogy between streamlined magnetic and solid obstacles

Analogies are elaborated in the qualitative description of two systems: the magnetohydrodynamic (MHD) flow moving through a region where an external local magnetic field (magnetic obstacle) is applied, and the ordinary hydrodynamic flow around a solid obstacle. The former problem is of interest both practically and theoretically, and the latter one is a classical problem being well understood in ordinary hydrodynamics. The first analogy is the formation in the MHD flow of an impenetrable region -- core of the magnetic obstacle -- as the interaction parameter $N$, i.e. strength of the applied magnetic field, increases significantly. The core of the magnetic obstacle is streamlined both by the upstream flow and by the induced cross stream electric currents, like a foreign insulated insertion placed inside the ordinary hydrodynamic flow. In the core, closed streamlines of the mass flow resemble contour lines of electric potential, while closed streamlines of the electric current resemble contour lines of pressure. The second analogy is the breaking away of attached vortices from the recirculation pattern produced by the magnetic obstacle when the Reynolds number $Re$, i.e. velocity of the upstream flow, is larger than a critical value. This breaking away of vortices from the magnetic obstacle is similar to that occurring past a real solid obstacle. Depending on the inlet and/or initial conditions, the observed vortex shedding can be either symmetric or asymmetric.Comment: minor changes, accepted for PoF, 26 pages, 7 figure

Structure of the Wake of a Magnetic Obstacle

We use a combination of numerical simulations and experiments to elucidate the structure of the flow of an electrically conducting fluid past a localized magnetic field, called magnetic obstacle. We demonstrate that the stationary flow pattern is considerably more complex than in the wake behind an ordinary body. The steady flow is shown to undergo two bifurcations (rather than one) and to involve up to six (rather than just two) vortices. We find that the first bifurcation leads to the formation of a pair of vortices within the region of magnetic field that we call inner magnetic vortices, whereas a second bifurcation gives rise to a pair of attached vortices that are linked to the inner vortices by connecting vortices.Comment: 4 pages, 5 figures, corrected two typos, accepted for PR

Large-scale intermittency of liquid-metal channel flow in a magnetic field

We predict a novel flow regime in liquid metals under the influence of a magnetic field. It is characterised by long periods of nearly steady, two-dimensional flow interrupted by violent three-dimensional bursts. Our prediction has been obtained from direct numerical simulations in a channel geometry at low magnetic Reynolds number and translates into physical parameters which are amenable to experimental verification under laboratory conditions. The new regime occurs in a wide range of parameters and may have implications for metallurgical applications.Comment: 10 pages, 4 figure

Theory of the Lorentz force flowmeter

A Lorentz force flowmeter is a device for the contactless measurement of flow rates in electrically conducting fluids. It is based on the measurement of a force on a magnet system that acts upon the flow. We formulate the theory of the Lorentz force flowmeter which connects the measured force to the unknown flow rate. We first apply the theory to three specific cases, namely (i) pipe flow exposed to a longitudinal magnetic field, (ii) pipe flow under the influence of a transverse magnetic field and (iii) interaction of a localized distribution of magnetic material with a uniformly moving sheet of metal. These examples provide the key scaling laws of the method and illustrate how the force depends on the shape of the velocity profile and the presence of turbulent fluctuations in the flow. Moreover, we formulate the general kinematic theory which holds for arbitrary distributions of magnetic material or electric currents and for any velocity distribution and which provides a rational framework for the prediction of the sensitivity of Lorentz force flowmeters in laboratory experiments and in industrial practice.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/58171/2/njp7_8_299.pd

Analytic solutions to determine critical magnetic fields for thermoelectric magnetohydrodynamics in alloy solidification

During alloy solidification, it has been observed that the morphology of microstructures can be altered by applying an external DC magnetic field. This structural change can be attributed to solutal convective transport introduced by thermoelectric magnetohydrodynamics (TEMHD) which drives fluid motion within the inter-dendritic region. Complex numerical models with grid resolutions on the microscopic scale have been constructed to solve the equations governing TEMHD. To complement these computationally intensive numerical models, analytic solutions were sought. Specifically, the analytic solutions presented herein are asymptotic solutions derived for TEMHD under low and high magnetic field intensities. Combination of these asymptotic solutions leads to simple formulae for estimating critical magnetic fields which can be readily evaluated in terms of characteristic lengths of materials that have been identified in experiments as key parameters of critical fields. Indeed, the critical magnetic fields predicted with the asymptotic solutions exhibit magnitudes consistent with those applied in current ongoing experiments where significant changes in microstructure have been observed. The capability to predict accurate results indicates that the analytic solutions described herein are valuable precursors not only for detailed numerical simulations but also for experimental design to study critical magnetic fields in alloy solidification

Evidence-informed development of engineering practical work: Effecting change through staff and student engagement

This paper discusses innovations in curriculum development in the Department of Engineering at the University of Cambridge as a participant in the Teaching for Learning Network (TFLN), a teaching and learning development initiative funded by the Cambridge-MIT Institute a pedagogic collaboration and brokerage network. A year-long research and development project investigated the practical experiences through which students traditionally explore engineering disciplines, apply and extend the knowledge gained in lectures and other settings, and begin to develop their professional expertise. The research project evaluated current practice in these sessions and developed an evidence-base to identify requirements for new activities, student support and staff development. The evidence collected included a novel student 'practice-value' survey highlighting effective practice and areas of concern, classroom observation of practicals, semi-structured interviews with staff, a student focus group and informal discussions with staff. Analysis of the data identified three potentially 'high-leverage' strategies for improvement: development of a more integrated teaching framework, within which practical work could be contextualised in relation to other learning; a more transparent and integrated conceptual framework where theory and practice were more closely linked; development of practical work more reflective of the complex problems facing professional engineers. This paper sets out key elements of the evidence collected and the changes that have been informed by this evidence and analysis, leading to the creation of a suite of integrated practical sessions carefully linked to other course elements and reinforcing central concepts in engineering, accompanied by a training and support programme for teaching staff