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  • 151.
    Draxler, J.
    et al.
    Luleå University of Technology, Luleå, 97187, Sweden.
    Edberg, J.
    Luleå University of Technology, Luleå, 97187, Sweden.
    Andersson, Joel
    University West, Department of Engineering Science, Division of Welding Technology.
    Lindgren, L. -E
    Luleå University of Technology, Luleå, 97187, Sweden.
    Modeling and simulation of weld solidification cracking part III: Simulation of solidification cracking in Varestraint tests of alloy 7182019In: Welding in the World, ISSN 0043-2288, E-ISSN 1878-6669Article in journal (Refereed)
    Abstract [en]

    Several advanced alloy systems are susceptible to weld solidification cracking. One example is nickel-based superalloys, which are commonly used in critical applications such as aerospace engines and nuclear power plants. Weld solidification cracking is often expensive to repair, and if not repaired, can lead to catastrophic failure. This study, presented in three papers, presents an approach for simulating weld solidification cracking applicable to large-scale components. The results from finite element simulation of welding are post-processed and combined with models of metallurgy, as well as the behavior of the liquid film between the grain boundaries, in order to estimate the risk of crack initiation. The first paper in this study describes the crack criterion for crack initiation in a grain boundary liquid film. The second paper describes the model required to compute the pressure and thickness of the liquid film required in the crack criterion. The third and final paper describes the application of the model to Varestraint tests of alloy 718. The derived model can fairly well predict crack locations, crack orientations, and crack widths for the Varestraint tests. The importance of liquid permeability and strain localization for the predicted crack susceptibility in Varestraint tests is shown. © 2019, The Author(s).

  • 152.
    Draxler, Joar
    et al.
    Luleå University of Technology, Luleå, 97187, Sweden.
    Edberg, J.
    Luleå University of Technology, Luleå, 97187, Sweden.
    Andersson, Joel
    University West, Department of Engineering Science, Division of Welding Technology.
    Lindgren, L. -E
    Luleå University of Technology, Luleå, 97187, Sweden.
    Modeling and simulation of weld solidification cracking part I: A pore-based crack criterion2019In: Welding in the World, ISSN 0043-2288, E-ISSN 1878-6669, Vol. 63, no 5, p. 1489-1502Article in journal (Refereed)
    Abstract [en]

    Several advanced alloy systems are susceptible to weld solidification cracking. One example is nickel-based superalloys, which are commonly used in critical applications such as aerospace engines and nuclear power plants. Weld solidification cracking is often expensive to repair and, if not repaired, can lead to catastrophic failure. This study, presented in three papers, presents an approach for simulating weld solidification cracking applicable to large-scale components. The results from finite element simulation of welding are post-processed and combined with models of metallurgy, as well as the behavior of the liquid film between the grain boundaries, in order to estimate the risk of crack initiation. The first paper in this study describes the crack criterion for crack initiation in a grain boundary liquid film. The second paper describes the model for computing the pressure and the thickness of the grain boundary liquid film, which are required to evaluate the crack criterion in paper 1. The third and final paper describes the application of the model to Varestraint tests of alloy 718. The derived model can fairly well predict crack locations, crack orientations, and crack widths for the Varestraint tests. The importance of liquid permeability and strain localization for the predicted crack susceptibility in Varestraint tests is shown. © 2019, The Author(s).

  • 153.
    Edberg, Jonas
    et al.
    Luleå University of Technology, 971 87 Luleå, Sweden.
    Andersson, Joel
    University West, Department of Engineering Science, Division of Welding Technology.
    Use of Indicators for Hot and Warm Cracking in Welded Structures2017In: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 7, p. 145-150Article in journal (Refereed)
    Abstract [en]

    Weight reduction of mechanical components is becoming increasingly important as a way to provide more environment friendly production and operation of different equipment. This is true in almost any manufacturing industry, but is especially important to the aerospace industry. Casting has often been replaced by hot and cold metal working operations and welding, usually including an additional heat treatment. This gives components better material properties and provides components with less weight and cost but with increased strength and efficiency. This may even be true for rotating Ni- based superalloy components, and is enabled by welding methods. However, weld cracking of precipitation hardening Ni-based superalloys is a serious problem, both in manufacturing and overhaul since it endangers component life if cracks are allowed to propagate. Cracks can appear in a weld and in it’s surroundings. The triggering mechanisms depend on its location and when it is nucleated. Generally saying, weld cracking in precipitation hardening Ni-based superalloys consists of two different types of cracking, hot cracking and warm cracking which may be further divided into heat affected zone (HAZ) liquation cracking, solidification cracking and strain age cracking, respectively. Finite element simulations of welding and heat treatment processes started in the seventies for small laboratory set-up cases and have today matured, and are now used on large-scale structures like aerospace components. But FE-based crack criteria that can predict the risk of cracking due to welding or heat treatments are rare. In a recent study both hot cracking and warm cracking have been investigated in Ni-based superalloys, and two FE-based indicators showing the risk of hot and warm cracks have been proposed. The objective of the investigation presented in this paper is to compare results from FE-simulations with experimental results from weldability tests, like the Varestraint test and the high temperature mechanical Gleeble test. © 2016

  • 154.
    Edstorp, Marcus
    University West, Department of Technology, Mathematics and Computer Science, Division for Mechanical Engineering.
    A Comparison between Moving Mesh Implementations for Metal Deposition Simulations2006In: Proceedings of the Nordic COMSOL Conference: Lyngby, Denmark, 2006, p. 107-110Conference paper (Other academic)
  • 155.
    Edstorp, Marcus
    University West, Department of Technology, Mathematics and Computer Science, Division for Mechanical Engineering.
    A Simplifed Finite Element Formulation for Spray Transfer GMA Weld Pools2008In: Progress in Industrial Mathematics at ECMI 2006, Springer , 2008, p. 822-826Conference paper (Refereed)
    Abstract [en]

    This chapter is concerned with the matter of mathematically modelling and computationally simulating the thermo and fluid dynamical phenomena occuring in the workpiece during a gas metal arc welding (GMAW) process, and does so by employing a continuum mechanical approach and a finite element formulation for approximating the solution of equations expressing the continuity of mass, the balance of linear momentum, the conservation of energy and the motion of the weld pool surface. GMAW is an electrode arc fusion welding process. The designation arc fusion signifies that an electric arc is struck between the welding electrode and the workpiece, and this causes the base material to melt on either side of the joint. During the subsequent solidification this will cause fusion between the workpiece parts. The electrode consist in a filler metal, and it is hence consumed during the process and molten droplets are, under the influence of electromagnetical and gravitational forces, transferred to the liquid weld pool. Mass is thus added to the workpiece and this causes a reinforcement of the joint.

  • 156.
    Edstorp, Marcus
    University West, Department of Engineering Science, Division of Production Engineering.
    An Investigation of Mesh Moving Methods for Simulating the Deformation of Incompressible Fluid Bodies 2009In: COMSOL Conference: 14-16 okt. 2009, Milan, 2009Conference paper (Other academic)
    Abstract [en]

    In this article we apply a finite element method for approximating the geometrical deformation of a two dimensional incompressible fluid body the flow velocity of which is not constrained along its top boundary. As a pressure force is applied on the free boundary, the domain occupied by the fluid deforms. There are several well established methods for treating this type of problem. The purpose of the present work is to investigate the computational efficiency of a number domain-mapping methods, which are akin to many solid mechanical applications involving large deformations, in that they employ a mapping of the initial configuration range onto the current. However, in fluid dynamical applications the deformation of the fluid body may be very large and contain several vortices. When employing domain-mapping methods, the spatial representations of the element domains are attached to the motion, and the Lagrange formulation is therefore inadequate. Instead we wish to find a motion which minimizes the element deformations and the computational complexity of the problem, while satisfying the kinematic constraint along the boundaries.

     

  • 157.
    Edstorp, Marcus
    et al.
    University West, Department of Engineering Science, Division of Production Engineering.
    Charles, Corinne
    University West, Department of Engineering Science, Division of Production Engineering.
    A Finite Element Methodology for Simulating the Influence of Process Parameters on the Phase Transitions in a GTA weld2009In: Proceedings of the 15th International Conference on the Joining of Materials                , 2009Conference paper (Other academic)
  • 158.
    Ekberg, Johanna
    et al.
    Chalmers University of Technology, Department of Industrial and Materials Science, Gothenburg, Sweden.
    Ganvir, Ashish
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Klement, Uta
    Chalmers University of Technology, Department of Industrial and Materials Science, Gothenburg, Sweden.
    Creci, Simone
    Chalmers University of Technology, Department of Chemistry and Chemical Engineering, Gothenburg, Sweden.
    Nordstierna, Lars
    Chalmers University of Technology, Department of Chemistry and Chemical Engineering, Gothenburg, Sweden.
    The Influence of Heat Treatments on the Porosity of Suspension Plasma-Sprayed Yttria-Stabilized Zirconia Coatings2018In: Journal of thermal spray technology (Print), ISSN 1059-9630, E-ISSN 1544-1016, Vol. 27, no 3, p. 391-401Article in journal (Refereed)
    Abstract [en]

    Suspension plasma-sprayed coatings are produced using fine-grained feedstock. This allows to control the porosity and to achieve low thermal conductivity which makes the coatings attractive as topcoats in thermal barrier coatings (TBCs). Used in gas turbine applications, TBCs are exposed to high temperature exhaust gases which lead to microstructure alterations. In order to obtain coatings with optimized thermomechanical properties, microstructure alterations like closing of pores and opening of cracks have to be taken into account. Hence, in this study, TBC topcoats consisting of 4 mol.% yttria-stabilized zirconia were heat-treated in air at 1150 °C and thereafter the coating porosity was investigated using image analysis (IA) and nuclear magnetic resonance (NMR) cryoporometry. Both IA and NMR cryoporometry showed that the porosity changed as a result of the heat treatment for all investigated coatings. In fact, both techniques showed that the fine porosity decreased as a result of the heat treatment, while IA also showed an increase in the coarse porosity. When studying the coatings using scanning electron microscopy, it was noticed that finer pores and cracks disappeared and larger pores grew slightly and achieved a more distinct shape as the material seemed to become more compact.

  • 159.
    Ekberg, Johanna
    et al.
    Chalmers University of Technology, Department of Materials and Manufacturing Technology,Göteborg, Sweden.
    Klement, Uta
    Chalmers University of Technology, Department of Materials and Manufacturing Technology,Göteborg, Sweden.
    Björklund, Stefan
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Analysis of single splats produced by axial suspension plasma spraying2018In: Surface Engineering, ISSN 0267-0844, E-ISSN 1743-2944, Vol. 34, no 5, p. 407-411Article in journal (Refereed)
    Abstract [en]

    Axial suspension plasma spraying (ASPS) is a relatively new, innovative technique with which microstructures have been produced that are similar to the ones produced by electron beam physical vapor deposition. They have a columnar structure and consist of nm- and µm-sized pores. However, so far the formation of the microstructure is not fully understood because fragmentation and vaporisation of the liquid significantly affects the deposition process. Analysis of single splats can provide important information on the phenomena controlling the coating formation process and the final coating properties. Therefore, the present study aims at providing first results of 8 wt-% yttria-stabilised zirconia single splats sprayed onto a steel substrate by use of ASPS. Scanning electron microscopy and atomic force microscopy have been used to characterise the splats with respect to appearance, shape, and size distribution. © 2017 Institute of Materials, Minerals and Mining Published by Taylor & Francis on behalf of the Institute

  • 160.
    Eklund, J.
    et al.
    Chalmers University of Technology, Energy and Materials, Department of Chemistry and Chemical Engineering, Göteborg, 412 96, Sweden.
    Phother, J.
    Chalmers University of Technology, Energy and Materials, Department of Chemistry and Chemical Engineering, Göteborg, 412 96, Sweden.
    Sadeghi, Esmaeil
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Joshi, Shrikant V.
    University West, Department of Engineering Science, Research Enviroment Production Technology West.
    Liske, J.
    Chalmers University of Technology, Energy and Materials, Department of Chemistry and Chemical Engineering, Göteborg, 412 96, Sweden.
    High-Temperature Corrosion of HVAF-Sprayed Ni-Based Coatings for Boiler Applications2019In: Oxidation of Metals, ISSN 0030-770X, E-ISSN 1573-4889, Vol. 91, no 5-6, p. 729-747Article in journal (Refereed)
    Abstract [en]

    The present study investigates the initial corrosion behaviour of HVAF-sprayed NiCr, NiAl and NiCrAlY coatings in two different environments, O 2 + H 2 O and O 2 + H 2 O + KCl at 600 °C for up to 168 h in order to evaluate the possibility of utilizing such coatings in biomass- and waste-fired boilers. SEM/EDX analysis showed that all coatings displayed a protective behaviour in O 2 + H 2 O. Upon addition of KCl (O 2 + H 2 O + KCl), the corrosion behaviour of the NiCr coating drastically changed as it formed a thick oxide layer and displayed major chlorine diffusion down to the substrate. The NiCrAlY coating displayed a significantly better corrosion resistance with only minor oxide formation. The NiAl coating exhibited a protective behaviour similar to when exposed in the absence of KCl indicating that a thin protective oxide has formed on the coating surface. The performance of the NiAl and NiCrAlY coatings is promising for future studies with long-term exposures in more corrosive environments such as in a biomass- and waste-fired boiler. © 2019, The Author(s).

  • 161.
    Elefante, Arianna
    et al.
    University of Bari, Physics Department, Via Amendola 173, 70126 Bari, Italy.
    Nilsen, Morgan
    University West, Department of Engineering Science, Division of Production Systems.
    Sikström, Fredrik
    University West, Department of Engineering Science, Division of Production Systems.
    Christiansson, Anna-Karin
    University West, Department of Engineering Science, Division of Production Systems.
    Maggipinto, Tommaso
    University of Bari, Physics Department, Via Amendola 173, 70126 Bari, Italy.
    Ancona, Antonio
    University West, Department of Engineering Science, Division of Production Systems. IFN-CNR Institute for Photonics and Nanotechnologies, Physics Department, Via Amendola 173, 70126 Bari, Italy.
    Detecting beam offsets in laser welding of closed-square-butt joints by wavelet analysis of an optical process signal2019In: Optics and Laser Technology, ISSN 0030-3992, E-ISSN 1879-2545, Vol. 109, p. 178-185Article in journal (Refereed)
    Abstract [en]

    Robotized laser beam welding of closed-square-butt joints is sensitive to the positioning of the laser beam with respect to the joint since even a small offset may result in a detrimental lack of sidewall fusion. An evaluation of a system using a photodiode aligned coaxial to the processing laser beam confirms the ability to detect variations of the process conditions, such as when there is an evolution of an offset between the laser beam and the joint. Welding with different robot trajectories and with the processing laser operating in both continuous and pulsed mode provided data for this evaluation. The detection method uses wavelet analysis of the photodetector signal that carries information of the process condition revealed by the plasma plume optical emissions during welding. This experimental data have been evaluated offline. The results show the potential of this detection method that is clearly beneficial for the development of a system for welding joint tracking.

  • 162.
    Ericson Öberg, Anna
    et al.
    Material- och Tillverkningsteknik, Chalmers.
    Johansson, Martin
    Holm, Erik
    Hammersberg, Peter
    Material- och Tillverkningsteknik, Chalmers.
    Svensson, Lars-Erik
    University West, Department of Engineering Science, Division of Production Engineering.
    The Influence of Correct Transfer of Weld Information on Production Cost2012In: 5th Swedish Production Symposium 2012, SPS12: 6-8 nov 2012, Linköping / [ed] Mats Björkman, Linköping, 2012, p. 295-302Conference paper (Other academic)
    Abstract [en]

    This study aims at identifying the causes for deviations between actual and theoretical weld weight. Previous performed studies have shown examples of up to 40% extra weld consumables used in some cases. One consequence is of course higher production cost but it can also give increased weight leading to higher fuel consumption and decreased payload. An interesting aspect is that generous margins on specific production measures dilute important feedback of process variation information preventing and prolonging structural root cause analysis.

    The causes for the observed deviations can heritage from several areas, both technical and within the information handling. The investigation shows that single components of the information structure and system, such as unsuitable demands as well as incapable evaluation methods, significantly influences the reliability of the entire manufacturing process. The common factor concerning when problems occur, seems to be the ability of correct information transfer between different functions in the organisation preventing the mismatch to appear in the interface. Suggestions for improving this situation include cross functional agreements as well as new measuring methods.

  • 163.
    Ericson Öberg, Anna
    et al.
    Chalmers, Gothenburg, Sweden.
    Åstrand, Erik
    University West, Department of Engineering Science, Research Enviroment Production Technology West. Volvo Construct Equipment, Braås, Sweden.
    Improved productivity by reduced variation in gas metal arc welding (GMAW)2017In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 92, no 1-4, p. 1027-1038Article in journal (Refereed)
    Abstract [en]

    The purpose of the research conducted is to describe the consequences of variation in the welding industry and the effect it has on manufacturing productivity. The potential has shown to be hidden in unnecessarily stringent requirements and over-processing. This has been studied in steps: customer requirements, design and analysis, preparation, welding, and assessment. The effect of variation in each step has been analyzed including estimations of its productivity improvement potential. Theoretically, in a perfect situation, with customized requirements and eliminated variation, more than half of all welding could be removed. Such a reduction is certainly neither practical nor possible. However, a sensible, controlled reduction could still have a very high impact. The financial implications are therefore substantial. The improved productivity of the manufacturing resources could be used for business development and increased production. To be able to realize the potential, interdisciplinary efforts are necessary. Management across different functions need to agree on the intended product life and make decisions thereafter.

  • 164.
    Ericsson, Mikael
    University West, Department of Technology.
    Simulation of robotic TIG-welding2003Licentiate thesis, comprehensive summary (Other academic)
  • 165.
    Ericsson, Mikael
    et al.
    University West, Department of Technology, Mathematics and Computer Science, Division for Mechanical Engineering.
    Bolmsjö, Gunnar
    University West, Department of Engineering Science, Division of Automation Systems.
    Nylén, Per
    University West, Department of Engineering Science, Research Enviroment Production Technology West.
    Three-dimensional simulation of robot path and heat transfer of a TIG-welded part with complex geometry2002In: 11th International Conferences on Computer Technology in Welding: Colombus, Ohio December 6-7, 2001, 2002, p. 309-316Conference paper (Other academic)
    Abstract [en]

    The application of commercial software (OLP) packages for robot simulation, and programming, use interactive computer graphics, provide powerful tools for creating welding paths off-line. By the use of such software, problems of robot reach, accessibility, collision and timing can be eliminated during the planning stage. This paper describes how such software can be integrated with a numerical model that predicts temperature-time histories in the solid material. The objective of this integration is to develop a tool for the engineer where robot trajectories and process parameters can be optimized on parts with complex geometry. Such a tool would decrease the number of weld trials, increase productivity and reduce costs. Assumptions and principles behind the modeling techniques are presented together with experimental evaluation of the correlation between modeled and measured temperatures.

  • 166.
    Ericsson, Mikael
    et al.
    University West, Department of Technology, Mathematics and Computer Science.
    Nylén, Per
    University West, Department of Technology, Mathematics and Computer Science.
    A look at the optimization of robot welding speed based on process modelling2007In: Welding Journal, ISSN 0043-2296, Vol. 86, no 8, p. 238-244Article in journal (Refereed)
    Abstract [en]

    Simulation tools to search for optimal process parameters are of great interest to reduce the number of experiments and thereby reduce cost and production time. In this paper, robot simulation has been used in combination with finite element simulations to optimize robot speed in order to minimize distortion while keeping complete joint penetration. In an earlier work performed by the authors, a finite element model was developed to predict heat transfer and residual stresses of parts with complex shapes. An interface between a robot simulation model and a finite element analysis model was also constructed. In this paper, an iterative method for robot speed optimization has been developed using MATLAB. The algorithm is designed to maintain complete joint penetration while maximizing productivity by utilizing the fastest weld speed. The method makes it possible to optimize the heat input to the component and thereby minimize component deformation for parts with complex shapes. The system was evaluated on stainless steel plates with varying thicknesses. Robot weld paths were defined off line and automatically downloaded to the finite element software where the optimization was performed. Simulations and experimental validations are presented.

  • 167.
    Ericsson, Mikael
    et al.
    University West, Department of Technology, Mathematics and Computer Science.
    Nylén, Per
    University West, Department of Technology, Mathematics and Computer Science.
    Berglund, D.
    Ling-Peng, R.
    Three dimensional simulation of robot path, heat transfer and residual stresses of a welded part with complex geometry2005In: International jourrnal for the joining of materials, ISSN 0905-6866, Vol. 17, no 2, p. 42-51Article in journal (Refereed)
    Abstract [en]

    In this article a simulation system is presented that combines computer aided robotics software used to define the welding operation, with a finite element model that predicts temperature-time histories and residual stress distributions for welding applications. The objective is to develop a tool for engineering processes in which robot trajectories and welding process parameters can be optimized off-line on parts with complex geometries. The system was evaluated on a stainless steel gas turbine component. Temperature dependent properties and phase change were included in the analysis. The turbine component was welded using an in-house TIG welding cell. The assumptions and principles that underpin the modeling techniques are presented together with predicted temperature histories, residual stresses, and fixture forces. Predicted residual stresses were compared with neutron diffraction measurements.

  • 168.
    Ericsson, Mikael
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Zhang, Xiaoxiao
    University West, Department of Engineering Science, Division of Production Systems.
    Christiansson, Anna-Karin
    University West, Department of Engineering Science, Division of Production Systems.
    Virtual Commissioning of Machine Vision Applications in Aero Engine Manufacturing2018In: Proceedings of The 15th International Conference on Control,Automation, Robotics and Vision, November 18-21, 2018, 2018, p. 1947-1952, article id 0293Conference paper (Refereed)
    Abstract [en]

    New aero engine design puts new demands on the manufacturing methods with increased automation level. Therefore, the use of vision sensors for control and guiding of industrial robots is being increasingly used. In such system, it is need to customise the machine vision system with real components in the real environment which is normally done close to the start-up of the production. This paper addresses a new concept for designing, programming, analysing, testing and verifying a machine vision application early in the design phase, called Virtual Machine Vision. It is based on a robot simulation software where the real machine vision application is simulated before the implementation in the production line. To verify the Virtual Machine Vision concept an advanced stereo vision application was used. Using two captured images from the robot simulated environment, camera calibration, image analysis and stereo vision algorithms are applied to determine a desired welding joint. The information of the weld joint, i.e. robot position and orientation for the weld path, are sent from the machine vision system to the robot control system in the simulation environment and the weld path is updated. The validation of the Virtual Machine Vision concept using the stereo vision application is promising for industrial use, and it is emphasised that the same programs are used in the virtual and real word.

  • 169.
    Eriksson, Robert
    et al.
    Siemens AG, Large Gas Turbines, Huttenstr. 12, 10553, Berlin, Germany.
    Gupta, Mohit Kumar
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Broitman, Esteban
    Linköping University. IFM, 58183, Linköping, Sweden.
    Jonnalagadda, Krishna Praveen
    Linköping University, IEI, 58183, Linköping, Sweden.
    Nylén, Per
    University West, Department of Engineering Science, Division of Production Engineering.
    Lin Peng, Ru
    Linköping University, IEI, 58183, Linköping, Sweden.
    Stresses and Cracking During Chromia-Spinel-NiO Cluster Formation in TBC Systems2015In: Journal of thermal spray technology (Print), ISSN 1059-9630, E-ISSN 1544-1016, Vol. 24, no 6, p. 1002-1014Article in journal (Refereed)
    Abstract [en]

    Thermal barrier coatings (TBC) are used in gas turbines to reduce the temperatures in the underlying substrate. There are several mechanisms that may cause the TBC to fail; one of them is cracking in the coating interface due to extensive oxidation. In the present study, the role of so called chromia-spinel-NiO (CSN) clusters in TBC failure was studied. Such clusters have previously been found to be prone to cracking. Finite element modeling was performed on a CSN cluster to find out at which stage of its formation it cracks and what the driving mechanisms of cracking are. The geometry of a cluster was obtained from micrographs and modeled as close as possible. Nanoindentation was performed on the cluster to get the correct Young’s moduli. The volumetric expansion associated with the formation of NiO was also included. It was found that the cracking of the CSN clusters is likely to occur during its last stage of formation as the last Ni-rich core oxidizes. Furthermore, it was shown that the volumetric expansion associated with the oxidation only plays a minor role and that the main reason for cracking is the high coefficient of thermal expansion of NiO. © 2015 ASM International

  • 170. Eriksson, Robert
    et al.
    Gupta, Mohit Kumar
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Broitman, Esteban
    Linköping University.
    Jonnalagadda, Krishna Praveen
    Linköping University.
    Nylén, Per
    University West, Department of Engineering Science, Research Environment Production Technology West.
    Peng, Ru Lin
    Linköping University.
    Stress and Cracking during Chromia-Spinel-NiO Cluster Formation in Thermal Barrier Coating Systems2015In: Journal of thermal spray technology (Print), ISSN 1059-9630, E-ISSN 1544-1016, Vol. 24, no 6, p. 1002-1014Article in journal (Refereed)
    Abstract [en]

    Thermal barrier coatings (TBC) are used in gas turbines to reduce the temperatures in the underlying substrate. There are several mechanisms that may cause the TBC to fail; one of them is cracking in the coating interface due to extensive oxidation. In the present study, the role of so called chromia-spinel-NiO (CSN) clusters in TBC failure was studied. Such clusters have previously been found to be prone to cracking. Finite element modeling was performed on a CSN cluster to find out at which stage of its formation it cracks and what the driving mechanisms of cracking are. The geometry of a cluster was obtained from micrographs and modeled as close as possible. Nanoindentation was performed on the cluster to get the correct Young's moduli. The volumetric expansion associated with the formation of NiO was also included. It was found that the cracking of the CSN clusters is likely to occur during its last stage of formation as the last Ni-rich core oxidizes. Furthermore, it was shown that the volumetric expansion associated with the oxidation only plays a minor role and that the main reason for cracking is the high coefficient of thermal expansion of NiO.

  • 171.
    Eynian, Mahdi
    University West, Department of Engineering Science, Division of Manufacturing Processes.
    Frequency Domain Study of Vibrations above and under Stability Lobes in Machining Systems2014In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 14, p. 164-169Article in journal (Refereed)
    Abstract [en]

    Using modified Nyquist contours, the dominant poles of the closed loop delay-differential equation for machining systems such as milling are identified. Contours with constant damping ratio of the dominant poles are constructed using this method. These contours are similar in shape to the stability lobes, but move upwards and to the right as the instability parameter increases. Additionally, it is possible to study the movement of the dominant poles to the right-hand side of the complex plane as the system becomes unstable by increasing the depth of cut at a constant spindle speed. The movement of the dominant pole is shown to be towards the right (unstable) and upward (higher vibration frequency) of the complex plane. In some cases, there would be a jump of vibration frequency due to the change of the lobe number. It is also shown that the damping ratio of the structure strongly affects both the vibration frequency and the damping ratio of the dominant poles in the closed loop system. Finally, in two milling experiments with two different spindle speeds and continuously increasing depth of cuts, vibration frequencies are measured and compared to the theoretical predictions. The measurements agree with the theoretical predictions, particularly in the unstable cutting conditions.

  • 172.
    Eynian, Mahdi
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    In-process identification of modal parameters using dimensionless relationships in milling chatter2019In: International journal of machine tools & manufacture, ISSN 0890-6955, E-ISSN 1879-2170, Vol. 143, p. 49-62Article in journal (Refereed)
    Abstract [en]

    Machining parameters needed for stable, high-performance high-speed machining could be found using mathematical models that need accurate measurements of modal parameters of the machining system. In-process modal parameters, however, can slightly differ from those measured offline and this can limit the applicability of simple measurement methods such as impact hammer tests. To study and extract the in-process modal parameters, mathematical models are used to define two key dimensionless parameters and establish their relationships with each other and the modal parameters. Based on these relationships, the modal parameters are extracted using two analytical methods, the two-point method (TPM), and the regression method (RM). As shown with experimental studies, the RM extracts the modal parameters successfully and while being much faster than the existing iteration-based methods, it provides stability lobe predictions that match well the experimental results. Furthermore, it is noted that the natural frequency parameter is estimated with much better relative precision compared to the damping ratio and the modal stiffness parameters. © 2019 Elsevier Ltd

  • 173.
    Eynian, Mahdi
    University West, Department of Engineering Science, Division of Manufacturing Processes.
    Prediction of vibration frequencies in milling using modified Nyquist method2015In: CIRP - Journal of Manufacturing Science and Technology, ISSN 1755-5817, E-ISSN 1878-0016, Vol. 11, no November, p. 73-81Article in journal (Refereed)
    Abstract [en]

    Study of the vibration frequencies at different cutting conditions is an alternative to the use of impact hammer test for identification of natural frequencies of the machining structure and calculation of stability lobe diagrams. Vibration frequencies not only depend on the natural frequencies of the structure, but also they are dependent on the spindle speed, damping ratio of the structure and the depth of cut. Ignoring these additional parameters would lead to errors in identification of the natural frequencies of the system and considerable deviation of the calculated stability lobe diagrams from actual cutting tests. In this study modified Nyquist method is used to investigate the effects of spindle speed, depth of cut and damping ratio of the structure on vibration frequencies. The quality of frequency prediction is compared to linear and nonlinear time domain simulations and machining experiments.

  • 174.
    Eynian, Mahdi
    University West, Department of Engineering Science, Division of Manufacturing Processes.
    Vibration frequencies in stable and unstable milling2015In: International journal of machine tools & manufacture, ISSN 0890-6955, E-ISSN 1879-2170, Vol. 90, p. 44-49Article in journal (Refereed)
    Abstract [en]

    Vibration frequencies in machining may be employed for calculation of natural frequencies of the dominant modes in chatter and selection of chatter-free spindle speeds with large material removal rates. In this approach, it is important to investigate the relationship between the vibration frequencies, the natural frequencies, spindle speeds and depth of cuts for both stable and unstable cutting conditions. In this paper, the dominant poles of the closed loop time delay differential equation of a milling operation are calculated by successive sectioning of the complex plane and using Cauchy's argument principle. Vibration frequency and damping ratio of the closed loop machining system for each cutting condition is calculated based on the position of the dominant pole on the complex plane which provides 3D plots of the vibration frequency and closed loop damping ratio over any range of depth of cuts and spindle speeds. Finally, the findings of the analytical approach are compared to a machining experiment and a time domain simulation and differences and similarities in their predictions are discussed.

  • 175.
    Eynian, Mahdi
    et al.
    University West, Department of Engineering Science, Division of Production Engineering.
    Altintas, Y
    University of British Columbia, Department of Mechanical Engineering, Manufacturing Automation Laboratory.
    Analytical Chatter Stability of Milling With Rotating Cutter Dynamics at Process Damping Speeds2010In: Journal of manufacturing science and engineering, ISSN 1087-1357, E-ISSN 1528-8935, Vol. 132, no 2Article in journal (Refereed)
    Abstract [en]

    Thispaper presents a chatter stability prediction method for milling flexibleworkpiece with end mills having asymmetric structural dynamics. The dynamicchip thickness regenerated by the vibrations of the rotating cutterand the fixed workpiece is transformed into the principle modaldirections of the rotating tool. The process damping is modeledas a linear function of vibration velocity. The dynamics ofthe milling system is modeled by a time delay matrixdifferential equation with time varying directional factors and speed dependentelements. The periodic directional factors are averaged over a spindleperiod, and the stability of the resulting time invariant butspeed dependent characteristic equation of the system is investigated usingthe Nyquist stability criterion. The stability model is verified withtime domain numerical simulations and milling experiments.

  • 176.
    Eynian, Mahdi
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Das, Kallol
    University West, Department of Engineering Science.
    Wretland, Anders
    GKN Aerospace Engine Systems AB, Trollhättan, Sweden.
    Effect of tool wear on quality in drilling of titaniumalloy Ti6Al4V, Part I: Cutting Forces, BurrFormation, Surface Quality and Defects2017In: High speed machining, E-ISSN 2299-3975, Vol. 3, p. 1-10Article in journal (Refereed)
    Abstract [en]

    Titanium's Ti6Al4V, alloy is an important material with a wide range of applications in the aerospace industry.Due to its high strength, machining this material for desired quality at high material removal rate is challenging and may lead to high tool wear rate. As a result,this material may be machined with worn tools and the effects of tool wear on machining quality need to be investigated.In this experimental paper, it is shown how drills of various wear levels affect the cutting forces, surface quality and burr formation. Furthermore, it is shown that high cutting forces and high plastic deformation, along with high temperatures that arise in cutting with worn tools may lead to initiation of microscopic cracks in the workpiece material in proximity of the drilling zone.

  • 177.
    Eynian, Mahdi
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Magnevall, Martin
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. Sandvik Coromant AB, Sandviken, 81181, Sweden.
    Cedergren, Stefan
    GKN Aerospace Sweden AB, Trollhättan, 46138, Sweden.
    Wretland, Anders
    GKN Aerospace Sweden AB, Trollhättan, 46138, Sweden.
    Lundblad, Mikael
    Sandvik Coromant AB, Sandviken, 81181, Sweden.
    New methods for in-process identification of modal parameters in milling2018In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 77, p. 469-472Article in journal (Refereed)
    Abstract [en]

    Chatter vibrations encountered in machining can degrade surface finish and damage the machining hardware. Since chatter originates from unstable interaction of the machining process and the machining structure, information about vibration parameters of the machining structure should be used to predict combinations of cutting parameters that allow stable machining. While modal test methods, for example those with impact hammers, are widely used to identify structural parameters; the need for sophisticated test equipment is prohibitive in their use. Furthermore, dynamic properties of critical components of a machine tool may change as they get affected by cutting loads, material removal and spindle rotation. Recently few algorithms have been proposed that identify the in-process dynamic parameters by frequency measurements, thus avoiding these problems. In this paper, some of these algorithms are reviewed and their capabilities and limitations in processing am experimental data set are compared and discussed. © 2018 The Authors. Published by Elsevier Ltd.

  • 178.
    Eynian, Mahdi
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Wretland, Anders
    GKN Aerospace Engine Systems AB, Trollhättan, Sweden.
    Sensitivity of Axis Tracking Errors of Machine Tools to Tool Wear in Drilling2016In: The 7th International Swedish Production Symposium, SPS16, Conference Proceedings: 25th – 27th of October 2016, Lund: Swedish Production Academy , 2016, p. 1-7Conference paper (Refereed)
    Abstract [en]

    Axis Tracking Errors (ATEs) of the active and inactive axis of numerically controlled machine tools are presented as new means of detection of tool wear that forgo expensive sensors or modifications of the machining structure, however, very little has been published about their capabilities or limitations as signal source for monitoring. In this paper the ATEs and cutting forces in drilling tests in two different machine tools, with drills of varying wear levels are measured. The sensitivity to wear is compared by introducing Percent Deviation from New Tool (PDFNT) factor, which is applied to the peak-to-peak values of the signals. While the ATEs are very small in magnitude, they are highly sensitive to wear levels, with PDFNTs reaching to 1000% for some axis. In addition, the standard deviation of PDFNTs calculated in drilling of seven holes with the same tool represents the repeatability of ATEs. The PDFNTs for ATEs are rather repeatable, but less repeatable than the PDFNTs of the axial drilling force. Furthermore it is shown that ATEs of different machine tools have different levels of sensitivity to wear levels which necessitates calibrating of monitoring systems using ATEs for each machine tool separately.

  • 179.
    Fahlström, Karl
    University West, Department of Engineering Science, Research Enviroment Production Technology West.
    Laser welding of boron steels for light-weight vehicle applications2015Licentiate thesis, comprehensive summary (Other academic)
    Abstract [en]

    Laser beam welding has gained a significant interest during the last two decades. The suitability of the process for high volume production has the possibility to give a strong advantage compared to several other welding methods. However, it is important to have the process in full control since various quality issues may otherwise occur. During laser welding of boron steels quality issues such as imperfections, changes in local and global geometry as well as strength reduction can occur. The aspects that need to be considered are strongly depending on alloy content, process parameters etc. These problems that can occur could be fatal for the construction and the lowest level of occurrence is wanted, independent of industry.

    The focus of this study has been to investigate the properties of laser welded boron steel. The study includes laser welding of boron alloyed steels with strengths of 1500 MPa and a recently introduced 1900 MPa grade. Focus has been to investigate weldability and the occurrence of cracks, porosity and strength reducing microstructure that can occur during laser welding, as well as distortion studies for tolerances in geometry. The results show that both conventional and 1900 MPa boron alloyed steel are suitable for laser welding.

    Due to the martensitic structure of welds the material tends to behave brittle. Cracking and porosity do not seem to be an issue limiting the use of these steels. For tolerances in geometry for larger structures tests has been done simulating laser welding of A-pillars and B-pillars. Measurements have been done with Vernier caliper as well as a more advanced optical method capturing the movements during the welding sequence. Results from the tests done on Ushaped beams indicates that depending on the geometry of the structure and heat input distortions can be controlled to give distortions from 1 to 8 mm, at a welding length of 700 mm. This means that important geometry points can be distorted several millimeters if the laser welding process not is controlled.

  • 180.
    Fahlström, Karl
    University West, Department of Engineering Science, Research Enviroment Production Technology West.
    Laser welding of ultra-high strength steel and a cast magnesium alloy for light-weight design2019Doctoral thesis, comprehensive summary (Other academic)
    Abstract [en]

    There is a strong industrial need for developing robust and flexible manufacturing methods for future light-weight design. Better performing, environmental friendly vehicles will gain competitive strength from using light weight structures. In this study, focus has been on laser welding induced distortions for ultra-high strength steel (UHSS) where trials were performed on single hat and double hat beams simulating A-pillar and B-pillar structures. Furthermore, also laser welding induced porosity in cast magnesium alloy AM50 for interior parts were studied. For UHSS, conventional laser welding was done in a fixture designed for research. For cast magnesium, single-spot and twin-spot welding were done. Measurements of final distortions and metallographic investigations have been performed. The results show that the total weld metal volume or the total energy input were good measures for predicting the distortions within one steel grade. For comparing different steel grades, the width of the hard zone should be used. The relation between the width of the hard zone, corresponding to the martensitic area of the weld, and the distortions is almost linear. Additionally, compared with continuous welds, stitching reduced the distortions. For cast magnesium, two-pass (repeated parameters) welding with single-spot gave the lowest porosity of approximately 3%. However, two-pass welding is not considered production friendly. Twin-spot welding was done, where the first beam provided time for nucleation and some growth of pores while reheating by the second beam should provide time for pores to grow and escape. This gave a porosity of around 5%. Distortions and porosity are the main quality problems that occur while laser welding UHSS and cast magnesium, respectively. Low energy input seems to generally minimize quality issues. Laser welding shows high potential regarding weld quality and other general aspects such as productivity in light-weight design for both high strength steel and cast magnesium.

  • 181.
    Fahlström, Karl
    et al.
    University West, Department of Engineering Science, Research Enviroment Production Technology West. Swerea KIMAB in Kista.
    Andersson, O.
    Volvo Cars in Torslanda & KTH in Stockholm, Sweden.
    Melander, A.
    Swerea KIMAB in Kista, Sweden.
    Karlsson, Leif
    University West, Department of Engineering Science, Division of Welding Technology.
    Svensson, Lars-Erik
    University West, Department of Engineering Science, Division of Welding Technology.
    Correlation between laser welding sequence and distortions for thin sheet structures2017In: Science and technology of welding and joining, ISSN 1362-1718, E-ISSN 1743-2936, Vol. 22, no 2, p. 150-156Article in journal (Refereed)
    Abstract [en]

    Thin ultra-high strength steel shaped as 700 mm long U-beams have been laser welded in overlap configuration to study the influence of welding sequence on distortions. Three different welding directions, three different energy inputs as well as stitch welding have been evaluated, using resistance spot welding (RSW) as a reference. Transverse widening at the ends and narrowing at the centre of the beam were measured. A clear correlation was found between the weld metal volume and distortion. For continuous welds there was also a nearly linear relationship between the energy input and distortion. However, the amount of distortion was not affected by a change in welding direction. Stitching and RSW reduced distortion significantly compared to continuous laser welding.

  • 182.
    Fahlström, Karl
    et al.
    University West, Department of Engineering Science, Research Enviroment Production Technology West. University West, Department of Engineering Science, Research Environment Production Technology West.
    Andersson, Oscar
    Volvo Cars, Torslanda, Sweden.
    Karlsson, Leif
    University West, Department of Engineering Science, Research Enviroment Production Technology West.
    Svensson, Lars-Erik
    University West, Department of Engineering Science, Division of Production Engineering. University West, Department of Engineering Science, Division of Welding Technology.
    Metallurgical effects and distortions in laser welding of thin sheet steels with variations in strength2017In: Science and technology of welding and joining, ISSN 1362-1718, E-ISSN 1743-2936, Vol. 22, no 7, p. 573-579Article in journal (Refereed)
    Abstract [en]

    Geometrical distortions occur while welding, but the understanding of how and why they occur and how to control them is limited. The relation between the weld width, weld metal volume, total energy input, width of hard zone and distortions when laser welding three different thin sheet steels with varying strength has therefore been studied. Weld metal volume and total energy input show a good correlation with distortion for one steel at a time. The best correlation with the when including all three steel grades was the width of the hard zone composed of weld metal and the martensitic area in the heat affected zone. © 2017 Institute of Materials, Minerals and Mining. Published by Taylor & Francis on behalf of the Institute.

  • 183.
    Fahlström, Karl
    et al.
    University West, Department of Engineering Science, Research Enviroment Production Technology West. Joining Technology, Swerea KIMAB, Kista 164 40, Sweden .
    Andersson, Oscar
    Volvo Cars, Torslanda 418 78, Sweden and XPRES, KTH Royal Institute of Technology, Stockholm 100 44, Sweden.
    Todal, Urban
    Volvo Cars, Torslanda 418 78, Sweden.
    Melander, Arne
    Joining Technology, Swerea KIMAB, Kista 164 40, Sweden and XPRES, KTH Royal Institute of Technology, Stockholm 100 44, Sweden.
    Minimization of distortions during laser welding of ultra high strength steel2015In: Journal of laser applications, ISSN 1042-346X, E-ISSN 1938-1387, Vol. 27, no 2, SI, article id S29011Article in journal (Refereed)
    Abstract [en]

    Ultra high strength steels are frequently used within the automotive industry for several components. Welding of these components is traditionally done by resistance spot welding, but to get further productivity and increased strength, laser welding has been introduced in the past decades. Fusion welding is known to cause distortions due to built in stresses in the material. The distortions result in geometrical issues during assembly which become the origin of low joint quality due to gaps and misfits. U-beam structures of boron steel simulating B-pillars have been welded with laser along the flanges. Welding parameters and clamping have been varied to create different welding sequences and heat input generating a range of distortion levels. The distortions have been recorded dynamically with an optical measurement system during welding. In addition, final distortions have been measured by a digital Vernier caliper. The combined measurements give the possibility to evaluate development, occurrence, and magnitude of distortions with high accuracy. Furthermore, section cuts have been analyzed to assess joint geometry and metallurgy. The results show that final distortions appear in the range of 0-8 mm. Distortions occur mainly transversely and vertically along the profile. Variations in heat input show clear correlation with the magnitude of distortions and level of joint quality. A higher heat input in general generates a higher level of distortion with the same clamping conditions. Section cuts show that weld width and penetration are significantly affected by welding heat input. The present study identifies parameters which significantly influence the magnitude and distribution of distortions. Also, effective measures to minimize distortions and maintain or improve joint quality have been proposed. Finally, transient finite element (FE) simulations have been presented which show the behavior of the profiles during the welding and unclamping process. (C) 2015 Laser Institute of America.

  • 184.
    Fahlström, Karl
    et al.
    University West, Department of Engineering Science, Research Enviroment Production Technology West. Swerea KIMAB, Joining Technology, Kista, Sweden .
    Andersson, Oscar
    Volvo Cars, Torslanda; XPRES, KTH Royal Institute of Technology.
    Todal, Urban
    Volvo Cars, Torslanda.
    Melander, Arne
    Swerea KIMAB, Joining Technology, Kista; XPRES, KTH Royal Institute of Technology, Stockholm.
    Minimization of distortions during laser welding of ultra-high strength steel2014In: ICALEO 2014 Congress proceedings, 2014, p. 1-10Conference paper (Refereed)
    Abstract [en]

    Ultra high strength steels are frequently used within the automotive industry for several components. Welding of these components is traditionally done by resistance spot welding, but to get further productivity and increased strength, laser welding has been introduced in the past decades. Fusion welding is known to cause distortions due to built-in stresses in the material. The distortions result in geometrical issues during assembly which become the origin of low joint quality due to gaps and misfits.

    U-beam structures of boron steel simulating B-pillars have been welded with laser along the flanges. Welding parameters and clamping have been varied to create different welding sequences and heat input generating a range of distortion levels. The distortions have been recorded dynamically with an optical measurement system during welding. In addition, final distortions have been measured by a digital Vernier caliper. The combined measurements give the possibility to evaluate development, occurrence and magnitude of distortions with high accuracy. Furthermore, section cuts have been analyzed to assess joint geometry and metallurgy.

    The results shows that final distortions appear in the range of 0-8 mm. Distortions occur mainly transversely and vertically along the profile. Variations in heat input show clear correlation with the magnitude of distortions and level of joint quality. A higher heat input in general generates a higher level of distortion with the same clamping conditions. Section cuts show that weld width and penetration are significantly affected by welding heat input.

    The present study identifies parameters which significantly influence the magnitude and distribution of distortions. Also, effective measures to minimize distortions and maintain or improve joint quality have been proposed.

    Finally, transient FE simulations have been presented which show the behavior of the profiles during the welding and unclamping process.

  • 185.
    Fahlström, Karl
    et al.
    Swerea KIMAB.
    Andersson, Oscar
    KTH Royal Institute of Technology.
    Todal, Urban
    Volvo Car Corporation.
    Melander, Arne
    Swerea KIMAB.
    Svensson, Lars-Erik
    University West, Department of Engineering Science, Division of Production Engineering.
    Karlsson, Leif
    University West, Department of Engineering Science, Divison of Natural Sciences, Surveying and Mechanical Engineering.
    Distortion Analysis in Laser Welding of Ultra High Strength Steel2014In: Proceedings of the 6th International Swedish Production Symposium 2014 / [ed] Stahre, Johan, Johansson, Björn & Björkman, Mats, 2014, p. 1-9Conference paper (Refereed)
    Abstract [en]

    Due to increased demands on reduced weight in automotive industries, the use of ultra high strength steels (UHSS) has increased. When laser welding UHSS sheets, heating and cooling of the material will cause geometrical distortions and may cause low joint quality. 700 mm long U-beam structures of 1 mm thick boron steel simulating structural pillars in body-in-white constructions have been welded along the flanges with different welding speeds to investigate distortions and weld quality. The results show that final distortions appear in the range of 0-8 mm. FE simulation methods have also been presented which generally predict the distribution of welding distortions.

  • 186.
    Fahlström, Karl
    et al.
    University West, Department of Engineering Science, Research Enviroment Production Technology West. Swerea KIMAB, Kista, University West, Sweden.
    Blackburn, Jon
    The Welding Institute, Great Britain.
    Karlsson, Leif
    University West, Department of Engineering Science, Division of Welding Technology.
    Svensson, Lars-Erik
    University West, Department of Engineering Science, Division of Welding Technology.
    Effect of Laser Welding Parameters on Porosity of Weldsin Cast Magnesium Alloy AM502018In: Modern Approaches on Material Science, ISSN 2641-6921, Vol. 1, no 2, p. 25-32Article in journal (Refereed)
    Abstract [en]

    Pores in the weld metal lower the mechanical properties of the weld. It is therefore important to understand the pore formation mechanisms and find procedures that could reduce porosity. This study focused on laser welding of 3 mm thick magnesium alloy AM50, investigating how different parameters affect porosity formation. Low levels of porosity content were achieved by either increasing the welding speed or using a two-pass welding approach. It was found that higher welding speeds did not allow pores,which were pre-existing from the die-casting process, to have sufficient time to coalesce and expand. In the two-pass welding technique, pores were removed as a result of a degassing process which occurred through the second pass.

  • 187.
    Fahlström, Karl
    et al.
    University West, Department of Engineering Science, Research Enviroment Production Technology West. Swerea KIMAB, Kista, Sweden.
    Blackburn, Jon
    TWI Ltd., Cambridge, UK.
    Karlsson, Leif
    University West, Department of Engineering Science, Division of Welding Technology.
    Svensson, Lars-Erik
    University West, Department of Engineering Science, Division of Welding Technology.
    Low Porosity in Cast Magnesium Welds by Advanced Laser Twin-Spot Welding2019In: Materials Sciences and Applications, ISSN 2153-117X, E-ISSN 2153-1188, Vol. 10, no 1, p. 53-64Article in journal (Refereed)
    Abstract [en]

    Porosity is reported to be a major issue when welding cast magnesium. Therefore, it is important to understand the pore formation mechanisms and find procedures that could be used to reduce porosity. This study investigated the possibility of using twin-spot optics for reducing the porosity in laser welded cast magnesium. Two twin-spot welding setups were compared using either a beam splitter or twin-spot welding with primary and secondary (placed in front of the primary optic) optics. The results showed that welding with a dual optic setup with a defocused secondary beam reduced the volumetric porosity in the weld to 5%. The highest levels of volumetric porosity were 30%, and were a result of using the dual optic setup, but with a defocused primary beam. No clear relation between the level of porosity and power or welding speed was found. It was found that the amount of porosity depended on the balance of the energy input (controlled by defocusing) between the two beams. Porosity formation can be reduced if the energy from the first beam results in the nucleation and initial growth of pores. Reheating by the second beam then allows the pores to grow and escape from the molten material without melting additional base material. Furthermore, twin-spot welding is shown to be a promising combination of a production friendly solution and high quality welding.

  • 188.
    Fahlström, Karl
    et al.
    University West, Department of Engineering Science, Research Environment Production Technology West.
    Larsson, Johnny
    Laser welding of 1900 MPa boron steels2013In: The 14th Nordic Laser Materials Processing Conference NOLAMP 14 / [ed] Alexander Kaplan, Hans Engström, Luleå: Luleå tekniska universitet, 2013, p. 15-24Conference paper (Other academic)
  • 189.
    Fahlström, Karl
    et al.
    University West, Department of Engineering Science, Research Enviroment Production Technology West.
    Persson, Kjell-Arne
    Swerea KIMAB, Joining Technology, Kista 164 40, Sweden.
    Larsson, Johnny K.
    Volvo Cars, Torslanda 405 31, Sweden.
    Vila Ferrer, Elisenda
    Gestamp, Barcelona 08635, Spain.
    Evaluation of laser weldability of 1800 and 1900 MPa boron steels2016In: Journal of laser applications, ISSN 1042-346X, E-ISSN 1938-1387, Vol. 28, no 2, article id 022426Article in journal (Refereed)
    Abstract [en]

    Ultrahigh strength steels are frequently used within the automotive industry. The driving force for use of these materials is to exchange thicker gauges to thinner and lighter structures. To get excellent strength and beneficial crash performance, the steel is microalloyed with boron which contributes to the 1500 MPa tensile strength. Increasing the carbon content will give superior tensile strength up to 2000 MPa. Welding of these components is traditionally done by resistance spot welding, but to get further productivity and increased stiffness of the structure, laser welding can be introduced. Welding of boron alloyed high strength steel is in general a stable and controlled process, but if increasing the carbon content quality issues such as cracking could possibly be a problem. In the present study, weldability of two different hardened boron steels with tensile strengths of 1800 and 1900 MPa, respectively, has been evaluated. Laser welding has been done in a lap joint configuration with 3.8–4.7 kW and varying welding speed between 3.5 and 5.5 m/min. As reference, results from more conventional 1500 MPa boron steel have been compared to 1800 and 1900 MPa boron steels to show the influence of the carbon content. Metallographic investigation, hot crack test, cold crack test, shear tensile, and cross-tension strength tests have been done. The results show that a weld quality similar to that for conventional boron steel can be achieved. Cracking and other defects can be avoided. As expected when welding martensitic steels, the failure mode in tensile testing is brittle. No weld defects have been found that influence strength. The sheet interface weld width, which together with stack-up thickness correlates with strength of the joint, could be increased by increasing the heat input and defocusing the laser beam. The effect of increased carbon content on weldability will be discussed more in detail, as well as the risk of cracking

  • 190.
    Farajian-Sohi, Majid
    et al.
    University West, Department of Technology, Mathematics and Computer Science.
    Järvstråt, Niklas
    University West, Department of Technology, Mathematics and Computer Science.
    A fractographical investigation of weld toe imperfections in tandem gas metal arc welding2006In: Steel Research International, ISSN 1611-3683, Vol. 77, no 12, p. 889-895Article in journal (Refereed)
    Abstract [en]

    Prediction and control of flaws in welds play important roles in design of complex structures against fatigue and fracture failure. Cold laps - outer lack of fusion - are small geometrical imperfections at weld toes, which act as fatigue crack initiation sites and reduce the life of welded structures drastically. The aim of this work is to characterize and categorize different types of such imperfections in the tandem gas metal arc welding process and find the mechanisms of their formation. Tandem welding process with different welding parameters was used to produce bead-on-plate coupons. These coupons were then sliced to smaller specimens for further investigations. For studying the weld toes, all the specimens were hit in an impact test machine and then the fracture surfaces of welds and base materials were analysed by scanning electron microscopy (SEM). Two types of cold laps were observed at weld toes, namely overlap and spatter. Observation and measurement showed that these imperfections are in the form of micro cracks with depth between 0.1 to 1.5mm and length between 0.1 to 4 mm.

  • 191.
    Fargas, G.
    et al.
    Universitat Politècnica de Catalunya, CIEFMA/EEBE, Departament de Ciència dels Materials i Enginyeria Metal·lúrgica, Barcelona, 08019, Spain. Centre for Research in Multiscale Engineering of Barcelona, Universitat Politècnica de Catalunya, Campus Diagonal Besòs-EEBE, Barcelona, 08019, Spain.
    Roa, J. J.
    Universitat Politècnica de Catalunya, CIEFMA/EEBE, Departament de Ciència dels Materials i Enginyeria Metal·lúrgica, Barcelona, 08019, Spain. Centre for Research in Multiscale Engineering of Barcelona, Universitat Politècnica de Catalunya, Campus Diagonal Besòs-EEBE, Barcelona, 08019, Spain.
    Sefer, B.
    Universitat Politècnica de Catalunya, CIEFMA/EEBE, Departament de Ciència dels Materials i Enginyeria Metal·lúrgica, Barcelona, 08019, Spain. Centre for Research in Multiscale Engineering of Barcelona, Universitat Politècnica de Catalunya, Campus Diagonal Besòs-EEBE, Barcelona, 08019, Spain. University of Erlangen-Nuremberg, Institute for Surface Science and Corrosion, Department of Materials Science and Engineering, Erlangen, D-91058, Germany.
    Pederson, Robert
    University West, Department of Engineering Science, Division of Welding Technology.
    Antti, M. -L
    Division of Materials Science, Luleå University of Technology, Luleå, S-97187, Sweden.
    Mateo, A.
    Universitat Politècnica de Catalunya, CIEFMA/EEBE, Departament de Ciència dels Materials i Enginyeria Metal·lúrgica, Barcelona, 08019, Spain. Centre for Research in Multiscale Engineering of Barcelona, Universitat Politècnica de Catalunya, Campus Diagonal Besòs-EEBE, Barcelona, 08019, Spain.
    Influence of cyclic thermal treatments on the oxidation behavior of Ti-6Al-2Sn-4Zr-2Mo alloy2018In: Materials Characterization, ISSN 1044-5803, E-ISSN 1873-4189, Vol. 145, p. 218-224Article in journal (Refereed)
    Abstract [en]

    Ti-6Al-2Sn-4Zr-2Mo is one of the most common titanium alloys for aerospace industry. This alloy experiences oxidation phenomenon at elevated temperatures. In the present study, cyclic thermal treatments were performed in air at 500, 593 and 700 °C, up to 500 cycles, in order to determine the oxidation kinetics and to analyze the oxide scale and alpha-case formation. Moreover, results were compared to those achieved under isothermal conditions to elucidate differences between both thermal conditions. In this sense, metallographic techniques and X-ray diffraction, together with a detailed advanced characterization of the microstructure by Field Emission Scanning Electron Microscopy and Focus Ions Beam, were used to analyze surface oxidation evolution. Results pointed out that cyclic treatments induced a strong increase of the weight gain compared to isothermal treatments. The analysis of the oxide scale revealed the formation of not only rutile, as isothermal treatments, but also anatase. Thickness of the oxide scale was higher for cyclic conditions, while alpha case did not exceed values reached by isothermal treatments and even became lower at 500 °C.

  • 192.
    Fargas, G.
    et al.
    Universitat Politècnica de Catalunya, CIEFMA/EEBE, Departament de Ciència dels Materials i Enginyeria Metal·lúrgica, Universitat Politècnica de Catalunya, Barcelona, Spain.
    Roa, J.J.
    Universitat Politècnica de Catalunya, CIEFMA/EEBE, Departament de Ciència dels Materials i Enginyeria Metallúrgica, Barcelona, Spain.
    Sefer, B.
    Universitat Politècnica de Catalunya, CIEFMA/EEBE, Departament de Ciència dels Materials i Enginyeria Metallúrgica, Barcelona, Spain, Luleå University of Technology, Division of Materials Science, S-97187 Luleå, Sweden.
    Pederson, Robert
    University West, Department of Engineering Science, Division of Welding Technology.
    Antti, M.-L.
    Luleå University of Technology, Division of Materials Science, S-97187 Luleå, Sweden.
    Mateo, A.
    Universitat Politècnica de Catalunya, CIEFMA/EEBE, Departament de Ciència dels Materials i Enginyeria Metallúrgica, Barcelona, Spain.
    Oxidation behavior of TI-6Al-4V alloy exposed to isothermal and cyclic thermal treatments2017In: Proceedings of the conference METAL 2017, TANGER Ltd. , 2017, p. 1573-1579Conference paper (Other academic)
    Abstract [en]

    One of the most common titanium alloys for aerospace industry is Ti-6Al-4V (usually designed as Ti-64) which is used for manufacturing aero-engine components, such as fan discs, compressor discs, blades andstators. The maximum service temperature for this alloy is limited partly because of degradation of mechanical properties at elevated temperatures (above 480 ºC). During the first stage of oxidation the oxidescale is protective, whereas after prolonged oxidation time it loses its protective nature and favours higher diffusion of oxygen through the oxide. In the present study, cyclic thermal treatments were performed in air at 500 and 700 ºC, up to 500 hours, and compared with similar studies carried out on isothermal oxidation conditions. The evolution of the surface oxidation was analyzed by metallographic techniques and X-ray diffraction, together with a detailed advanced characterization of the microstructure by Scanning Electron Microscopy and Focus Ions Beam. The results point out that the cyclic thermal treatments induced a strong increase of the weight gain compared to isothermal treatments. The analysis of the oxide scale revealed not only the presence of rutile, at 700 ºC, but also anatase and TiOx at 500 ºC for both isothermal and cyclic thermal treatments. At 700 ºC, thermal stress caused by cyclic thermal treatments promoted the fracture of the oxide after the first 20 hours.

  • 193.
    Fasth, Angelica
    et al.
    University West, Department of Engineering Science, Division of Production Engineering.
    Nylen, Per
    University West, Department of Engineering Science, Division of Production Engineering.
    Choi, B.
    Center for Theraml Spray Research, Stony Brook, New York.
    Klement, Uta
    Chalmers University.
    A Comparative studey of Mechanical Properties Between HVOF-spryed Maxphase Materials and Plasma Sprayed MCrAIY Coatings2009In: Surface Modification Technologies XXII: Proceedings of the Twenty Second International Conference on Surface Modification Technologies Held at University West, Trollhättan, Sweden September 22-24 2008 / [ed] T.S. Sudarshan & Per Nylen, VALAR Docs , 2009, p. 149-156Conference paper (Other academic)
  • 194.
    Fasth, Angelica
    et al.
    University West, Department of Engineering Science.
    Nylén, Per
    University West, Department of Engineering Science, Division of Production Engineering.
    Markocsan, Nicolaie
    University West, Department of Engineering Science.
    Musalek, Radek
    Characterization of thermo-mechanical properties for thermal sprayed NiCoCrAlY coatings2010In: Proceedings of the Thermal Spray: Global Solutions for Future Application (ITSC 2010) Conference: Singapore, May 3-5, 2010, 2010, p. 431-435Conference paper (Refereed)
  • 195.
    Ferreira Magalhães, Ana Catarina
    et al.
    University West, Department of Engineering Science, Division of Welding Technology.
    Cederqvist, L.
    SKB AB, Oskarshamn, Sweden.
    De Backer, Jeroen
    University West, Department of Engineering Science, Division of Production Systems.
    Håkansson, Emil
    Volvo Cars, Göteborg, Sweden.
    Ossiansson, Bruno
    Volvo Cars, Skövde, Sweden.
    Bolmsjö, Gunnar
    Linnaeus University, Växjö, Sweden.
    A Friction Stir Welding case study using Temperature Controlled Robotics with a HPDC Cylinder Block and dissimilar materials joining2019In: Journal of Manufacturing Processes, ISSN 1526-6125, Vol. 46, p. 177-184Article in journal (Refereed)
    Abstract [en]

    The automotive industry is going through a radical transformation from combustion engines to fully electric propulsion, aiming at improving key performance indicators related to efficiency, environmental sustainability and economic competitiveness. In this transition period, it is important to continue the innovation of combustion engines for e.g. plug-in hybrid vehicles. This led Volvo Cars to pursue radically new manufacturing processes such as Friction Stir Welding (FSW). The work presented in this paper is a case study whereby feasibility of using FSW to join a reinforcement element into the aluminium casted Cylinder Block was studied. The complex geometry of the joint required a flexible five-axis manipulator, i.e. an industrial robot, as well as advanced process control, i.e. temperature feedback control, in order to maintain a consistent weld quality throughout the whole component. The process was successfully demonstrated in a lab environment and offers a cost-efficient solution while maintaining the durability and higher efficiency. The outcome of this study shows the great potential of implementing the FSW process in combination with High Pressure Die Casted components, such a Cylinder Block. © 2019 The Society of Manufacturing Engineers

  • 196.
    Ferreira Magalhães, Ana Catarina
    et al.
    University West, Department of Engineering Science, Division of Welding Technology.
    De Backer, Jeroen
    University West, Department of Engineering Science, Division of Production Systems. TWI Ltd. Cambridge, UK.
    Martin, J
    TWI Ltd. Cambridge, UK.
    Bolmsjö, Gunnar
    Linnaeus University, Växjö, Sweden.
    In-situ temperature measurement in friction stir welding of thick section aluminium alloys2019In: Journal of Manufacturing Processes, ISSN 1526-6125, Vol. 39, p. 12-17Article in journal (Refereed)
    Abstract [en]

    Friction stir welding (FSW) is a reliable joining technology with a wide industrial uptake. However, several fundamentals of the process such as the temperature inside the stirred zone of the weld and its influence on mechanical properties, are not yet fully understood. This paper shows a method for accurate temperature measurements in multiple locations around the tool, to identify the location of the peak temperature, the temperature variations between the advancing and the retreating side of the tool and its relation to the tool geometry. Both standardised thermocouples in the FSW tool and the novel "tool-workpiece thermocouple" method were used to record temperatures.Bead-on-plate welds in 20 mm thickness AA6082-T6 were produced while the temperatures were measured in three locations on the FSW tool: at the shoulder outer diameter, at the transition from shoulder to probe and at the probe tip. It was found that the hottest point in the stirred zone was 607 °C and was located at the transition between the shoulder and probe, on the retreating-trailing side of the tool. The lowest temperature was found at the probe tip on the retreating-leading side of the tool.The results offer a better understanding of the temperature distribution around a FSW tool. The method presented can be applied to verification of thermal simulation models, tool design optimization, quality assurance and temperature feedback control.

  • 197.
    Fisk, Martin
    et al.
    Materials Science and Applied Mathematics, Malmö University.
    Andersson, Joel
    University West, Department of Engineering Science, Division of Manufacturing Processes. GKN Aerospace Engine Systems, Trollhättan.
    du Rietz, Rickard
    Materials Science and Applied Mathematics, Malmö University.
    Haas, Sylvio
    MAX IV Laboratory, Lund University.
    Hall, Stephen
    Division of Solid Mechanics, Lund University.
    Precipitate evolution in the early stages of ageing in Inconel 718 investigated using small-angle x-ray scattering2014In: Materials Science & Engineering: A, ISSN 0921-5093, E-ISSN 1873-4936, Vol. 612, p. 202-207Article in journal (Refereed)
    Abstract [en]

    Microstructural evolution during the early stages of ageing (less than one hour) in a Ni-Cr-Fe based superalloy Inconel 718 (IN718) has been investigated using Small-Angle X-ray Scattering (SAXS). The effects of precipitate kinetics on the precipitate size distribution are compared indirectly with SAXS measurements by using Vickers microhardness data. The microhardness increased after 4 min of ageing at a temperature of 760 degrees C, although the recorded SAXS data did not reveal the precipitate size distribution. This indicates that the precipitates had not evolved enough to be detected, but still a small number of precipitates increased the yield strength. After ageing the alloy for the shortest period for which data were available, 8 min, clear evidence of precipitates could be found from the SAXS data, showing that the gamma ‘’ - precipitates are about 6 nm in width and 3 nm in height. (C) 2014 Elsevier B.V. All rights reserved.

  • 198.
    Fisk, Martin
    et al.
    Malmö Högskola.
    Lundbäck, Andreas
    Luleå Tekniska Universitet.
    Andersson, Joel
    University West, Department of Engineering Science, Division of Manufacturing Processes.
    Lindgren, Lars-Erik
    Luleå Tekniska Universitet.
    Finite Element Analysis Using a Dislocation Density Based Flow Stress Model Coupled with Model for Precipitate Evolution2014In: 8th International Symposium on Superalloy 718 and Derivatives / [ed] E. Ott, A. Banik, J. Andersson, I. Dempster, T. Gabb, J. Groh, K. Heck, R. Helmink, X. Liu och A. Wusatowska-Sarnek, Hoboken, NJ, USA: John Wiley & Sons, 2014, p. 155-168Conference paper (Refereed)
  • 199.
    Fredriksson, Claes
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Sustainability of metal powder additive manufacturing2019In: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 33, p. 139-144Article in journal (Refereed)
    Abstract [en]

    Additive manufacturing, or 3D-printing, has attracted attention and raised expectations regarding future production and repair of parts, for example, in the aerospace industry. Various techniques have been utilized to deposit metal alloys for components. It has been suggested that this may offer great benefits in terms of sustainability, in particular, new opportunities for lightweighting. There are, however, outstanding questions about sustainability benefits outside of the use phase. In this paper, the material and manufacturing life-cycle stages were investigated for details produced using INCONEL 718. Energy measurements from an ARCAM A2X Electron Beam Melting system are presented and compared to the embodied energy and indirect CO2-emissions of the feedstock as well as to traditional subtractive manufacturing. It is found that both the metal powder production and the additive manufacturing process itself contribute considerably to total energy use and emissions. Ashby’s 5-step method for assessment of sustainable development is used to briefly discuss economic and social implications of additive manufacturing. © 2019 The Authors. Published by Elsevier B.V.

  • 200.
    Freton, Pierre
    et al.
    University Paul Sabatier, Toulouse, France.
    Choquet, Isabelle
    University West, Department of Engineering Science, Division of Manufacturing Processes.
    Gonzales, Jean-Jacques
    University Paul Sabatier, Toulouse, France.
    Teulet, Philippe
    University Paul Sabatier, Toulouse, France.
    Improvement of a pseudo kinetic method for the calculation of a two-temperature thermal plasma composition2013In: Proceedings of the XXth Symposium on Physics of Switching Arc, 2013, p. 139-142Conference paper (Refereed)
    Abstract [en]

    This paper proposes an improved Saha law for calculating the 2T composition of an Argon thermal plasma. This law is based on a simplified kinetic approach. The obtainedresults are compared with other laws from the literature (Van de Sanden, Pseudokinetic) and provide a satisfying qualitative behaviour.

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