R. Galgalikar

Modeling of ballistic-failure mechanisms in gas metal arc welds of mil a46100 armor-grade steel

Purpose – The purpose of this paper is to discuss the recently developed multi-physics computational model for the conventional Gas Metal Arc Welding (GMAW) joining process that has been upgraded with respect to its predictive capabilities regarding the spatial distribution of the mechanical properties controlling the ballistic limit (i.e. penetration resistance) of the weld. Design/methodology/approach – The original model consists of five modules, each dedicated to handling a specific aspect of the GMAW process, i.e.: electro-dynamics of the welding-gun; radiation-/convection-controlled heat transfer from the electric arc to the workpiece and mass transfer from the filler-metal consumable electrode to the weld; prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; and spatial distribution ...

Computer-aided engineering analysis of tooth-bending fatigue-based failure in horizontal-axis wind-turbine gearboxes

Purpose – Wind energy is one of the most promising and the fastest growing alternative-energy production technologies, which have been developed in response to stricter environmental regulations, the depletion of fossil-fuel reserves, and the worlds ever-growing energy needs. This form of alternative energy is projected to provide 20 percent of the US energy needs by 2030. For economic reasons, wind turbines (articulated structures that convert wind energy into electrical energy) are expected to operate, with only regular maintenance, for at least 20 years. However, some key wind turbine components (especially the gearbox) tend to wear down, malfunction and fail in a significantly shorter time, often three to five years after installation, causing an increase in the wind-energy cost and in the cost of ownership of the wind turbine. Clearly, to overcome this problem, a significant increase in long-term gearbox reliability needs to be achieved. Design/methodology/approach – While purely empirical efforts a...

Molecular- and Domain-level Microstructure-dependent Material Model for Nano-segregated Polyurea

Purpose – Polyurea is an elastomeric two-phase co-polymer consisting of nanometer-sized discrete hard (i.e. high glass transition temperature) domains distributed randomly within a soft (i.e. low glass transition temperature) matrix. A number of experimental investigations reported in the open literature clearly demonstrated that the use of polyurea external coatings and/or internal linings can significantly increase blast survivability and ballistic penetration resistance of target structures, such as vehicles, buildings and field/laboratory test-plates. When designing blast/ballistic-threat survivable polyurea-coated structures, advanced computational methods and tools are being increasingly utilized. A critical aspect of this computational approach is the availability of physically based, high-fidelity polyurea material models. The paper aims to discuss these issues. Design/methodology/approach – In the present work, an attempt is made to develop a material model for polyurea which will include the eff...

Wind-Turbine Gear-Box Roller-Bearing Premature-Failure Caused by Grain-Boundary Hydrogen Embrittlement: A Multi-physics Computational Investigation

To help overcome the problem of horizontal-axis wind-turbine (HAWT) gear-box roller-bearing premature-failure, the root causes of this failure are currently being investigated using mainly laboratory and field-test experimental approaches. In the present work, an attempt is made to develop complementary computational methods and tools which can provide additional insight into the problem at hand (and do so with a substantially shorter turn-around time). Toward that end, a multi-physics computational framework has been developed which combines: (a) quantum-mechanical calculations of the grain-boundary hydrogen-embrittlement phenomenon and hydrogen bulk/grain-boundary diffusion (the two phenomena currently believed to be the main contributors to the roller-bearing premature-failure); (b) atomic-scale kinetic Monte Carlo-based calculations of the hydrogen-induced embrittling effect ahead of the advancing crack-tip; and (c) a finite-element analysis of the damage progression in, and the final failure of a prototypical HAWT gear-box roller-bearing inner raceway. Within this approach, the key quantities which must be calculated using each computational methodology are identified, as well as the quantities which must be exchanged between different computational analyses. The work demonstrates that the application of the present multi-physics computational framework enables prediction of the expected life of the most failure-prone HAWT gear-box bearing elements.

Material-Model-Based Determination of the Shock-Hugoniot Relations in Nanosegregated Polyurea

Previous experimental investigations reported in the open literature have indicated that applying polyurea external coatings and/or internal linings can substantially improve ballistic penetration resistance and blast survivability of buildings, vehicles, and laboratory/field test-plates, as well as the blast-mitigation capacity of combat helmets. The protective role of polyurea coatings/linings has been linked to polyurea microstructure, which consists of discrete hard-domains distributed randomly within a compliant/soft matrix. When this protective role is investigated computationally, the availability of reliable, high-fidelity constitutive models for polyurea is vitally important. In the present work, a comprehensive overview and a critical assessment of a polyurea material constitutive model, recently proposed by Shim and Mohr (Int J Plast 27:868-886, 2011), are carried out. The review revealed that this model can accurately account for the experimentally measured uniaxial-stress versus strain data obtained under monotonic and multistep compressive loading/unloading conditions, as well as under stress relaxation conditions. On the other hand, by combining analytical and finite-element procedures with the material model in order to define the basic shock-Hugoniot relations for this material, it was found that the computed shock-Hugoniot relations differ significantly from their experimental counterparts. Potential reasons for the disagreement between the computed and experimental shock-Hugoniot relations are identified.

Ballistic-Failure Mechanisms in Gas Metal Arc Welds of Mil A46100 Armor-Grade Steel: A Computational Investigation

In our recent work, a multi-physics computational model for the conventional gas metal arc welding (GMAW) joining process was introduced. The model is of a modular type and comprises five modules, each designed to handle a specific aspect of the GMAW process, i.e.: (i) electro-dynamics of the welding-gun; (ii) radiation-/convection-controlled heat transfer from the electric-arc to the workpiece and mass transfer from the filler-metal consumable electrode to the weld; (iii) prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; (iv) the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; and (v) spatial distribution of the as-welded material mechanical properties. In the present work, the GMAW process model has been upgraded with respect to its predictive capabilities regarding the spatial distribution of the mechanical properties controlling the ballistic-limit (i.e., penetration-resistance) of the weld. The model is upgraded through the introduction of the sixth module in the present work in recognition of the fact that in thick steel GMAW weldments, the overall ballistic performance of the armor may become controlled by the (often inferior) ballistic limits of its weld (fusion and heat-affected) zones. To demonstrate the utility of the upgraded GMAW process model, it is next applied to the case of butt-welding of a prototypical high-hardness armor-grade martensitic steel, MIL A46100. The model predictions concerning the spatial distribution of the material microstructure and ballistic-limit-controlling mechanical properties within the MIL A46100 butt-weld are found to be consistent with prior observations and general expectations.

Prediction of the Grain-Microstructure Evolution Within a Friction Stir Welding (FSW) Joint via the Use of the Monte Carlo Simulation Method

A thermo-mechanical finite element analysis of the friction stir welding (FSW) process is carried out and the evolution of the material state (e.g., temperature, the extent of plastic deformation, etc.) monitored. Subsequently, the finite-element results are used as input to a Monte-Carlo simulation algorithm in order to predict the evolution of the grain microstructure within different weld zones, during the FSW process and the subsequent cooling of the material within the weld to room temperature. To help delineate different weld zones, (a) temperature and deformation fields during the welding process, and during the subsequent cooling, are monitored; and (b) competition between the grain growth (driven by the reduction in the total grain-boundary surface area) and dynamic-recrystallization grain refinement (driven by the replacement of highly deformed material with an effectively “dislocation-free” material) is simulated. The results obtained clearly revealed that different weld zones form as a result of different outcomes of the competition between the grain growth and grain refinement processes.

Computational analysis of gear-box roller-bearing white-etch cracking A multi-physics approach

Purpose – A simple economic analysis has revealed that in order for wind energy to be a viable alternative, wind-turbines (convertors of wind energy into electrical energy) must be able to operate for at least 20 years, with only regular maintenance. However, wind-turbines built nowadays do not generally possess this level of reliability and durability. Specifically, due to the malfunction and failure of drive-trains/gear-boxes, many wind-turbines require major repairs after only three to five years in service. The paper aims to discuss these issues. Design/methodology/approach – The subject of the present work is the so-called white etch cracking, one of the key processes responsible for the premature failure of gear-box roller-bearings. To address this problem, a multi-physics computational methodology is developed and used to analyze the problem of wind-turbine gear-box roller-bearing premature-failure. The main components of the proposed methodology include the analyses of: first, hydrogen dissolution...

Improved gas metal arc welding multi-physics process model and its application to MIL A46100 armor-grade steel butt-welds

Purpose – The purpose of this paper is to develop multi-physics computational model for the conventional gas metal arc welding (GMAW) joining process has been improved with respect to its predictive capabilities regarding the spatial distribution of the mechanical properties (strength, in particular) within the weld. Design/methodology/approach – The improved GMAW process model is next applied to the case of butt-welding of MIL A46100 (a prototypical high-hardness armor-grade martensitic steel) workpieces using filler-metal electrodes made of the same material. A critical assessment is conducted of the basic foundation of the model, including its five modules, each dedicated to handling a specific aspect of the GMAW process, i.e.: first, electro-dynamics of the welding-gun; second, radiation/convection controlled heat transfer from the electric arc to the workpiece and mass transfer from the filler-metal consumable electrode to the weld; third, prediction of the temporal evolution and the spatial distribu...

Computational investigation of foreign object damage sustained by environmental barrier coatings (EBCs) and SiC/SiC ceramic-matrix composites (CMCs)

Purpose – The purpose of this paper is to prevent their recession caused through chemical reaction with high-temperature water vapor, SiC-fiber/SiC-matrix ceramic-matrix composite (CMC) components used in gas-turbine engines are commonly protected with so-called environmental barrier coatings (EBCs). EBCs typically consist of three layers: a top thermal and mechanical protection coat; an intermediate layer which provides environmental protection; and a bond coat which assures good EBC/CMC adhesion. The materials used in different layers and their thicknesses are selected in such a way that the coating performance is optimized for the gas-turbine component in question. Design/methodology/approach – Gas-turbine engines, while in service, often tend to ingest various foreign objects of different sizes. Such objects, entrained within the gas flow, can be accelerated to velocities as high as 600 m/s and, on impact, cause substantial damage to the EBC and SiC/SiC CMC substrate, compromising the component integr...