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Professor Hongbiao Dong from the University of Leicester and Shuwen Wen, Principal Scientist at Tata Steel, describe their collaboration using HPC to model the welding process. For more information, please see http://hpc-midlands.ac.uk
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Leicester – Tata Steel collaboration
Hongbiao Dong1, Shuwen Wen2
1. University of Leicester 2. Tata Steel
HPC Midlands Launch Event
March 20, 2013
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Tata Steel: a multinational steel company, subsidiary of Tata
Fortune 500 company Top 10 global steelmaker: production
capacity 28 Mt/a Manufacturing operations
in 26 countries
Commercial presence inover 50 countries
80 000 employees
Listed in Mumbai
JamshedpurIndia
Port TalbotUK
IjmuidenThe Netherlands
3
Locations Tata Steel Group RD&T
UK total 350 people
IJmuiden 445 people
India total 450 people
JamshedpurIndia R&D
IJTC
TTC
STC
AEG
TTC: Teesside Technology Centre
STC: Swinden Technology Centre (Rotherham)
AEG: Automotive Engineering Group (Coventry)
IJTC: IJmuiden Technology Centre
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Tata Steel R, D&T Swinden Technology Centre (STC)
• Processes, Products and Applications
• Departments in:
• Iron making (TTC & IJTC)• Steel making & continuous casting• Steel Metallurgy• Iron making• Long Product Rolling• Rolling Metal Strip• Industrial & Construction• Environment
Rotherham S60 3AR, UK
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Department of Engineering
Top 200 universities worldwide*
Mechanics of Materials Group at Leicester
• At the interface between Mechanical Engineering and Materials Engineering.
• Research by integrating experimental and computational technologies.
• Our computational work benefits from ALICE and East Midlands HPC – ALICE: a new High Performance Computing (HPC) cluster at Leicester
Mechanics of Materials Group at Leicester
• At the interface between Mechanical Engineering and Materials Engineering.
• Research by integrating experimental and computational technologies.
• Our computational work benefits from ALICE and East Midlands HPC – ALICE: a new High Performance Computing (HPC) cluster at Leicester
• Multi-scale, Multi-physics Materials Process Modelling
• Casting, Welding, Heat Treatment
• Microstructure Evolution during Processing and In-use of High Temperature Materials
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What Can Materials Process Modelling Do ?
To visualize process routes
What are the physical processes occurring during processing (casting, welding, heat treatment and coating) ?
What are the optimum dimensions and geometry of components with regard to processing?
Can numerical modelling be used to answer the above questions?
Can we move away from empirical choices of casting, welding /HT/coating processes to one which is designed and optimised?
Multi-scale Multi-physical Nature of Materials Processing
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melting/solidification interface
heat conduction
workpiece A workpiece Bweld pool
J B
free surface
anode (+) marangoni
heat flux
cathode (-)radiation
Plasma gas drag
(a)
(b)
(c)
300 m300 m
1nm
3nm
crystal growth, element segregation
solute diffusion latent heat
grain boundary segregation
stresselastic/plastic-deformationintermetallic
structure defects
(d)
Energetics and kinetics of
interface, bonding strength
Crystal A Crystal B /Melt
arc pressure
filler wire (electrode)
scale (time/length)
quantum
(10-12s / 10-10 to 10-9m)thermodynamic data;
force fields, including H-alloy interaction;interfacial properties
Inter-atomic potentials
atomic arrangement at interfaces
classical
(10-7s / 10-9 to 10-8m)
interface structurethermodynamic properties of
solid-liquid & solid-solid interfaces
chemistry;crystal orientation; stress
nano-micro
(10-3s / 10-9 to 10-3m)
dendrite kinetics; solidification interface;
microscopic morphology
grain
(10-3 to 101s / 10-4 to 10-
2m)boundary conditions;
solidification fronts; mushy zone permeability
chemistry; flow pattern; thermal field
models
diffusion of hydrogen,
cohesive zone model
microstructure & chemistry, thermodynamics of
fracture/ defect growth, residual stress,
ab-initio quantum mechanical
molecular dynamics
phase field crystal phase field
grain structure model
computational fluid dynamics finite element analysis
macro
(102s / 10-3 to 10-1m)
structural integrity,
hot cracking +
hydrogen embrittlement
alloy-specific thermodynamics &
kinetics
Computational thermo-dynamics
latent heat; enthalpy change; grain structure; local chemistry; thermal field and local gradients
Models
Macro-scale: In-situ Observation of Internal Flow in Weld Pool
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remotely controlled metal active gas (MAG)
Return current
BeamSource Detector
welding head
10mm thicknesssteel plate
Insulating plate
Beamline sample stage
Lincoln Powertec 231C
welding machine
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Return current
BeamSource Detector
welding head
10mm thicknesssteel plate
Insulating plate
Beamline sample stage
Lincoln Powertec 231C
welding machine
single streamlines of flow
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(a) over 50 mini seconds
(b) over 120 mini seconds
(X-ray radiography)
Return current
BeamSource Detector
welding head
10mm thicknesssteel plate
Insulating plate
Beamline sample stage
Lincoln Powertec 231C
welding machine
(a)
(b)
flow trace over 0.1 s
advancing melt pool
electrode
solidified joint
solidified joint
flow trace over 0.23 s
advancing melt pool
electrode
Modelling work to analyse the internal flow
• The quantitative analysis of the fluid flow has been proven difficult, although progress has been made in analysing the velocity data.
• This is because different forces (plasma and arc pressure, Marangoni and Lorentz forces) act on fluid dynamics in weld pool.
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With Lorentz force driven flow (S=0%) Without Lorentz force driven flow (S=0%)
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Solid-liquid interface fluctuation
System: Pure Fe (100)[010] planeAtoms: 43,200System size: 17.545 1.7545 17.545 nmTime: 1ns, dt=5fs
Potential Impact
• Being able to predict and control properties using HPC during welding, and hence to produce welds with radically improved properties will certainly help improve the productivity of pipeline products and the integrity of the constructed gas and oil pipelines by using new alloys in conjunction with advanced technologies.
• The technique has been taking forward by industry to develop advanced welding technology for new welded pipelines, the construction time is usually 2 to 3 years in an European leading steel-making industry, during which welding development is a major issue.
• The overall cost involved in the development is several million Euros. When these pipeline products are in use, the cost for the construction of a pipeline is often up to several billion Euros and the integrity of the pipeline has huge implications for the local energy supply and hence economic prosperity.
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With the advances in HPC & processing modelling, Changes can be made in manufacturing?
Acknowledgement
EPSRC, the European Commission, the Royal Society , Tata Steel, Rolls-Royce, TWI,
for research funding
Colleagues and PhD students at University of Leicester, Loughborough University for providing information in
this presentation