Search Results (20)

As a main component of the magnetic pulse welding (MPW) system, the working coil exerts a great influence on the electromagnetic force and its distribution, which, in turn, affects the quality of the MPW joints. This study proposes a structural parameter optimization of the MPW coil, with the objective of achieving a higher induced current density on the flyer plate. The optimal Latin hypercube sampling technique (OLHS), Kriging approximate model, and the Non-Linear Programming by Quadratic Lagrangian (NLPQL) algorithm were employed in the optimization procedure, based on the finite element model built in LS-DYNA. The results of the sensitivity analysis indicated that all the selected parameters of the coil had a specific influence on the induced current density in the flyer plate. The optimized coil structure serves to refine the pulse current flowing path within the coil, effectively reducing the current loss within the coil. Additionally, the structure reduces the adverse effect of the current within the coil on the induced current within the flyer plate. Numerical results show the peak-induced current of the flyer plate increasing by 25.72% and the maximum Lorentz force rising by 58.10% at 25 kJ with the optimized coil structure. The experimental results show that with the same 25 kJ discharge energy, the optimized coil could increase the collision velocity from 359.92 m/s to 458.93 m/s. Moreover, 30 kJ of discharge energy should be needed to achieve the failure mode of base material failure with the original coil, while only 15 kJ should be applied to the optimized coil. These findings verify the optimization model and give some outline for coil design. Full article

Current progress in numerical simulations and machine learning allows one to apply complex loading conditions for the identification of parameters in plasticity models. This possibility expands the spectrum of examined deformed states and makes the identified model more consistent with engineering practice. A combined experimental-numerical approach to identify the model parameters and study the dynamic plasticity of metals is developed and applied to the case of cold-rolled OFHC copper. In the experimental part, profiled projectiles (reduced cylinders or cones in the head part) are proposed for the Taylor impact problem for the first time for material characterization. These projectiles allow us to reach large plastic deformations with true strains up to 1.3 at strain rates up to 10⁵ s⁻¹ at impact velocities below 130 m/s. The experimental results are used for the optimization of parameters of the dislocation plasticity model implemented in 3D with the numerical scheme of smoothed particle hydrodynamics (SPH). A Bayesian statistical method in combination with a trained artificial neural network as an SPH emulator is applied to optimize the parameters of the dislocation plasticity model. It is shown that classical Taylor cylinders are not enough for a univocal selection of the model parameters, while the profiled cylinders provide better optimization even if used separately. The combination of different shapes and an increase in the number of experiments increase the quality of optimization. The optimized numerical model is successfully validated by the experimental data about the shock wave profiles in flyer plate experiments from the literature. In total, a cheap, simple, but efficient route for optimizing a dynamic plasticity model is proposed. The dislocation plasticity model is extended to estimate grain refinement and volume fractions of weakened areas in comparison with experimental observations. Full article

Miniaturized laser-initiated pyrotechnic devices have great application prospects in aerospace and modern weapon systems due to their excellent energy output performance and reliability. In order to develop a low-energy insensitive laser detonation technology based on a two-stage charge structure, it is important to deeply analyze the motion law of a titanium flyer plate driven by the deflagration of the first-stage charge (RDX). The effects of the charge mass of RDX, flyer plate mass, and barrel length on the motion law of flyer plates were studied through a numerical simulation method based on the Powder Burn deflagration model. The consistency between the numerical simulation and the experimental results was analyzed using the paired t confidence interval estimation method. The results show that the Powder Burn deflagration model can effectively describe the motion process of the RDX deflagration-driven flyer plate with a 90% confidence level, and its velocity error is ≤6.7%. The speed of the flyer plate is proportional to the mass of the RDX charge, inversely proportional to the mass of the flyer plate, and exponentially related to its moving distance. As the moving distance of the flyer plate increases, the RDX deflagration products and air in front of the flyer plate are compressed, which inhibits the motion of the flyer plate. In the optimum state (the mass of the RDX charge is 60 mg, the mass of the flyer is 85 mg, and the length of the barrel is 3 mm), the speed of the titanium flyer reaches 583 m/s, and the peak pressure of the RDX deflagration reaches 2182 MPa. This work will provide a theoretical basis for the refined design of a new generation of miniaturized high-performance laser-initiated pyrotechnic devices. Full article

In this study, the tensile and shear strengths of aluminum 6061-differently grooved stainless steel 304 explosive clads are predicted using deep learning algorithms, namely the conventional neural network (CNN), deep neural network (DNN), and recurrent neural network (RNN). The explosive cladding process parameters, such as the loading ratio (mass of the explosive/mass of the flyer plate, R: 0.6–1.0), standoff distance, D (5–9 mm), preset angle, A (0–10°), and groove in the base plate, G (V/Dovetail), were varied in 60 explosive cladding trials. The deep learning algorithms were trained in a Python environment using the tensile and shear strengths acquired from 80% of the experiments, using trial and previous results. The remaining experimental findings are used to evaluate the developed models. The DNN model successfully predicts the tensile and shear strengths with an accuracy of 95% and less than 5% deviation from the experimental result. Full article

In this study, we experimentally investigate the high stain rate and spall behavior of Cantor high-entropy alloy (HEA), CoCrFeMnNi. First, the Hugoniot equations of state (EOS) for the samples are determined using laser-driven CoCrFeMnNi flyers launched into known Lithium Fluoride (LiF) windows. Photon Doppler Velocimetry (PDV) recordings of the velocity profiles find the EOS coefficients using an impedance mismatch technique. Following this set of measurements, laser-driven aluminum flyer plates are accelerated to velocities of 0.5–1.0 km/s using a high-energy pulse laser. Upon impact with CoCrFeMnNi samples, the shock response is found through PDV measurements of the free surface velocities. From this second set of measurements, the spall strength of the alloy is found for pressures up to 5 GPa and strain rates in excess of 10⁶ s⁻¹. Further analysis of the failure mechanisms behind the spallation is conducted using fractography revealing the occurrence of ductile fracture at voids presumed to be caused by chromium oxide deposits created during the manufacturing process. Full article

In this study, the energy deposited at the welding interface was controlled by changing the stand-off between the flyer and base plates. Pure titanium (TP 270C) and duplex stainless steel (SUS 821L1) were welded under 5- and 15-mm stand-offs, respectively. When the stand-off was 5 mm, the average wavelength and average amplitude of the welding interface were 271 and 61 μm, respectively; at 15 mm stand-off, the average wavelength and average amplitude of the welding interface were 690 and 192 μm, respectively. The differences between the two welding conditions were compared using a tensile test, fracture analysis, a 90° bending test, Vickers hardness, and nanoindentation related to the mechanical properties of materials. The experimental results indicated that the sample with a 5-mm stand-off had better mechanical properties. Full article

The shock wave damage during explosive welding has not been reported in a flyer Mo plate of the Mo/Cu clads. However, it would be an inevitable problem in group VI elements. This study was aimed to characterize the shock wave damage in the Mo plate, that is less brittle than a W plate, of explosive welded Mo/Cu clads. Cladding at low horizontal collision velocities leading to high collision angles was expected to enhance the shock wave damage, and the clads resulted in less elongation in bending tests. On the other hand, in the clads obtained at high horizontal collision velocities (HCVs) with low collision angles, their bending elongation increased significantly. The shock wave damage penetrated from the surface of a Mo plate to the Mo/Cu interface, and thus reducing thickness of a Mo plate of bending specimens increased bending plastic strain. The shock wave damage is associated with kinetic energy imparted to the flyer Mo plate, and thus loss of kinetic energy due to formation of an intermediate layer at the interface and reducing thickness of a flyer Mo plate would be very helpful for decrease of shock wave damage. Full article

A sweptback angle can directly regulate a leading-edge vortex on various aerodynamic devices as well as on the wings of biological flyers, but the effect of a sweptback angle has not yet been sufficiently investigated. Here, we thoroughly investigated the effect of the sweptback angle on aerodynamic characteristics of low-aspect-ratio flat plates at a Reynolds number of 2.85 × 10⁴. Direct force/moment measurements and surface oil-flow visualizations were conducted in the wind-tunnel B at the Technical University of Munich. It was found that while the maximum lift at an aspect ratio of 2.03 remains unchanged, two other aspect ratios of 3.13 and 4.50 show a gradual increment in the maximum lift with an increasing sweptback angle. The largest leading-edge vortex contribution was found at the aspect ratio of 3.13, resulting in a superior lift production at a sufficient sweptback angle. This is similar to that of a revolving/flapping wing, where an aspect ratio around three shows a superior lift production. In the oil-flow patterns, it was observed that while the leading-edge vortices at aspect ratios of 2.03 and 3.13 fully covered the surfaces, the vortex at an aspect ratio of 4.50 only covered up the surface approximately three times the chord, similar to that of a revolving/flapping wing. Based on the pattern at the aspect ratio of 4.50, a critical length of the leading-edge vortex of a sweptback plate was measured as ~3.1 times the chord. Full article

This study aimed to analyze the effect of the impact velocity of a Zr 700 flyer plate explosively welded to a Ti Gr. 1/P265GH bimetallic composite on the residual stress formation, structural properties, and tensile strength. The residual stresses were determined by the orbital hole-drilling strain-gauge method in a surface layer of Zr 700 in as-received and as-welded conditions. The analysis of the tensile test results based on a force parallel to interfaces was used to propose a model for predicting the yield force of composite plates. Compressive residual stresses found in the initial state of the Zr 700 plate were transformed to tensile stresses on the surface layer of the welded Zr 700 plate. A higher impact velocity resulted in higher tensile stresses in the Zr 700 surface layer. To increase the resistance of the composite plate to stress-based corrosion cracking, a lower value of impact velocity is recommended in the welding process. Full article

When metal is subjected to extreme strain rates, the conversation of energy to plastic power, the subsequent heat production and the growth of damages may lag behind the rate of loading. The imbalance alters deformation pathways and activates micro-dynamic excitations. The excitations immobilize dislocation, are responsible for the stress upturn and magnify plasticity-induced heating. The main conclusion of this study is that dynamic strengthening, plasticity-induced heating, grain size strengthening and the processes of microstructural relaxation are inseparable phenomena. Here, the phenomena are discussed in semi-independent sections, and then, are assembled into a unified constitutive model. The model is first tested under simple loading conditions and, later, is validated in a numerical analysis of the plate impact problem, where a copper flyer strikes a copper target with a velocity of 308 m/s. It should be stated that the simulations are performed with the use of the deformable discrete element method, which is designed for monitoring translations and rotations of deformable particles. Full article

Mg alloys are extensively used in various automotive, aerospace, and industrial applications. Their limited corrosion resistance can be enhanced by welding a thin Al plate onto the alloy surface. In this study, we perform the explosive welding of a thin Al plate, accelerated by the detonation of an explosive through a gelatin layer as a pressure-transmitting medium, onto two Mg alloy samples: Mg₉₆Zn₂Y₂ alloy containing a long-period stacking ordered phase in an α-Mg matrix and commercial AZ31. The bonding interface is characterized using optical microscopy, scanning electron microscopy, X-ray diffraction, and electron probe microanalysis. Under moderate experimental conditions, the thin Al plates are successfully welded onto the Mg alloys, showing typical wavy interfaces without intermediate layers. Due to the decreased energetic condition corresponding to the use of a thin flyer plate and gelatin medium, the resulting bonding quality is better than that obtained using a regular explosive welding technique. Further, based on the well-known window for explosive welding, we estimate that the experimental conditions for successful bonding are close to the lower welding limit for a thin Al plate with the two Mg alloys considered. These findings may contribute to improving the quality of materials welded with explosive welding. Full article

The ability to classify foods based on level of processing, not only conventional MyPlate food groups, might be a useful tool for consumers faced with a wide array of highly processed food products of varying nutritional value. The objective of this study was to assess the impact of a proof-of-concept nutrition education intervention on nutrition knowledge, assessed by correct classification of foods according to MyPlate food groups, MyPlate ‘limit’ status (for fat, sugar, sodium), and level of processing (NOVA categories). We utilized a randomized, controlled design to examine the impact of a MyPlate vs. combined MyPlate + NOVA intervention vs. control group. Intervention groups received educational flyers via email and participants were assessed using electronic baseline and follow-up surveys. The MyPlate + NOVA intervention group performed at least as well as the MyPlate group on classifying conventional food groups and ‘limit’ status. Moreover, the MyPlate + NOVA group far outperformed the other groups on classifying NOVA categories. Longer-term trials are needed, but our results suggest that NOVA principles may be more easily understood and applied than those of MyPlate. Education strategies focusing on level of food processing may be effective in the context of the modern food environment. Full article

The aim of this paper is to study the microstructure and mechanical properties of the Ti6Al4V/Al-1060 plate by explosive welding before and after heat treatment. The welded interface is smooth and straight without any jet trapping. The disturbances near the interface, circular and random pores of Al-1060, and beta phase grains of Ti6Al4V have been observed by Scanning electron microscopy (SEM). Heat treatment reduces pores significantly and generates a titanium-island-like morphology. Energy dispersive spectroscopy (EDS) analysis results show that the maximum portion of the interfacial zone existed in the aluminium side, which is composed of three intermetallic phases: TiAl, TiAl₂ and TiAl₃. Heat treatment resulted in the enlargement of the interfacial zone and conversion of intermentallic phases. Tensile test, shear test, bending test and hardness test were performed to examine the mechanical properties including welding joint qualities. The results of mechanical tests show that the tensile strength and welding joint strength of the interfacial region are larger than one of its constituent material (Al-1060), the microhardness near the interface is maximum. Besides, tensile strength, shear strength and microhardness of heat treated samples are smaller than unheat treated. Smooth particle hydrodynamic (SPH) method is used to simulate the transient behaviour of both materials at the interface. Transient pressure, plastic deformation and temperature on the flyer and base side during the welding process were obtained and analyzed. Furthermore, the numerical simulation identified that almost straight bonding structure is formed on the interface, which is in agreement with experimental observation. Full article

Bipolar plates are a major part of fuel cells, which are a clean and recyclable energy source. This study was carried out with two dies for a bipolar plate forming investigation with the magnetic pulse method: a bipolar plate die and a 10-channel die. With the bipolar plate die, the forming of bipolar plates with a Cu110 sheet and a Grade 2 Ti sheet indicated that the bipolar plate die needed optimization for a full replication. The obtained maximum average depth percentage was 86% for a Cu110 sheet, while it was 54% for a Grade 2 Ti sheet in this study. A further increase of the depth percentage is possible but requires a much higher capacitor bank energy. The increase of the capacitor bank energy would result in severe tearing, while the depth percentage increase was little. The primary current and flyer velocity were measured at various capacitor bank energies. With the 10-channel die, the die parameters’ effect on metal sheet forming was investigated with a Cu110 sheet and an SS201 sheet. The draft angle had a significant effect on the replication of the die surface. The full replication was achieved for channels with proper parameters with both a Cu110 sheet and an SS201 sheet. Therefore, the bipolar plate die could be optimized based on the 10-channel die results. Full article

The current work focuses on the effect of explosive ratio R on the comprehensive properties of Ti/Al clads manufactured via explosive welding. The lower and upper limits of explosive ratio, namely R₁ and R₂, were determined according to the R–δ_f (flyer plate thickness) welding window. Two TA2/1060 explosive cladding plates were successfully manufactured at the different explosive ratios. Microstructure investigation was conducted by optical microscopy (OM), scanning electron microscopy (SEM), and energy dispersive spectrometer (EDS). The small wave bonding interface was observed at R₁, where the vortex structure containing the ingot structure appeared periodically. The bonding interface presented a big wave bonding morphology and a locally continuous melting layer at R₂. Many prolonged grains and adiabatic shear bands (ASBs) were found near the interface for a greater explosive load. Intermetallic compounds were formed in the bonding zones of the two plates. The thickness of element diffusion area increased with an increasing explosive ratio. Comparative tests of mechanical properties indicated that the tensile shear strength at R₁ was higher. The microhardness, tensile strength, and bending performance of the two plates are similar and acceptable. Tensile fracture analysis indicated the fracture mode at R₁ was ductile fracture, while the explosive cladding plate at R₂ had mainly ductile fracture with quasi-cleavage fracture as the supplement. Full article