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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: closed (30 September 2023) | Viewed by 29768

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Special Issue Editors

Prof. Dr. Francesco De Bona

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Guest Editor

Department Polytechnic of Engineering and Architecture, University of Udine, Via delle Scienze 208, 33100 Udine, Italy
Interests: Finite Element Modeling; Thermo-Mechanical Simulation; Machine Design

Dr. Jelena Srnec Novak

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Guest Editor

Faculty of Engineering & Centre for Micro- and Nanosciences and Technologies, University of Rijeka, Vukovarska 58, 51000 Rijeka, Croatia
Interests: cyclic plasticity; material characterization; thermo-Mechanical fatigue; non-Linear finite element simulations; nanoindentation
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Dr. Francesco Mocera

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Guest Editor

Department of Mechanical and Aerospace Engineering (DIMEAS), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
Interests: hybrid and electric vehicles; lithium-ion batteries; multibody simulation; thermo-mechanical simulations
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Special Issue Information

Dear Colleagues,

Virtual prototyping techniques, generally based on numerical methods, are widely used in the design process of an industrial product. Over the last few decades, the demand for strong improvement in terms of productivity and reliability, accompanied by cost reduction requirements, have been fundamental considerations in the design, often requiring more than one simultaneously occurring physical fields (thermal, mechanical, electrical, metallurgical, etc.) to be taken into account. At present, a huge number of commercial codes have been developed to perform multiphysics simulations; nevertheless, the bottleneck to obtain reliable results is generally constituted by the availability of a suitable material model. The Special Issue is thus aimed at investigating metallic material modeling techniques for virtual prototypes with emphasis on both the theoretical basis and the experimental identification and verification. Special attention is addressed to simulation issues in metal forming and other metal processing technologies, in cyclic plasticity and thermal fatigue, in MEMs operation and soldering, in thermo-electro-mechanical modeling of electric vehicles components such as batteries, electric motors, electronics, and in any other topics where material modeling constitutes a crucial aspect to achieve a dependable virtual prototype.

The purpose of this Special Issue is to collect papers providing state-of-the-art knowledge on material modeling for multiphysics simulations. Researchers are encouraged to submit research as well as review papers on specific aspects of the proposed subject or also to describe applications in which the above-mentioned topics are applied to relevant engineering case studies.

Prof. Dr. Francesco De Bona
Dr. Jelena Srnec Novak
Dr. Francesco Mocera
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

multiphysics
numerical simulation
finite element method
nonlinear
thermomechanical
metal forming
shape memory
welding
electromechanical
lithium-ion
solder

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Published Papers (12 papers)

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Editorial

Jump to: Research

5 pages, 158 KiB

Open AccessEditorial

Material Modeling in Multiphysics Simulation

by Francesco De Bona, Francesco Mocera and Jelena Srnec Novak

Metals 2024, 14(3), 296; https://doi.org/10.3390/met14030296 - 1 Mar 2024

Viewed by 1237

Abstract

Virtual prototyping techniques, generally based on numerical methods, are widely used in the process of designing an industrial product [...] Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

Research

Jump to: Editorial

15 pages, 4238 KiB

Open AccessArticle

Study of the Free Randomly Moving Electron Transport Peculiarities in Metals

by Vilius Palenskis and Vytautas Jonkus

Metals 2023, 13(9), 1551; https://doi.org/10.3390/met13091551 - 3 Sep 2023

Cited by 1 | Viewed by 1297

Abstract

In this study, we review some aspects of the application of free randomly moving (RM) electron density and its probability density function distribution to the main free electron transport characteristics of elemental metals. It is shown that metal atom thermal vibrations not only produce free RM electrons, but also produce the same number of electronic defects (weakly shielded ions). The general expressions for the drift mobility, diffusion coefficient, and mean free path of randomly moving electrons are presented. It is shown that the scattering of free RM electrons is mainly due to electronic defects, which cause the distortion of the periodic potential (or the charge density) distribution in the periodic lattice. The resistivity of the elemental metal is caused by electronic defect scattering, taking into account the exchange in the thermal energies between phonons and free RM electrons. Special attention is paid to the analysis of the Hall effect measurement data: the Hall coefficient is presented for two types of RM electrons and holes, taking into account electron-like and hole-like densities of states. The paramagnetism and diamagnetism of the free RM electrons are simply explained using the definition of free RM electron density. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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13 pages, 3200 KiB

Open AccessArticle

Effectiveness of Travelling Slice Modeling in Representing the Continuous Casting Process of Large Product Sections

by Gianluca Bazzaro and Francesco De Bona

Metals 2023, 13(9), 1505; https://doi.org/10.3390/met13091505 - 22 Aug 2023

Cited by 1 | Viewed by 975

Abstract

It is critical in the metal continuous casting process to estimate the temperature evolution of the casted section along the machine from the meniscus (the point where liquid metal is poured) to the cutting machine, where the product is cut to commercial length. A convenient approximated model to achieve this goal with a feasible computational effort, particularly in the case of large sections, is the so-called travelling slice: the transversal section of casted product is subjected to different thermal boundary conditions (e.g., thermal flux, radiation, convection) that are found during the movement at constant speed from meniscus to the end of machine. In this work, the results obtained with the approximated travelling slice model are analyzed in the favorable case of an axisymmetric section. In this case, the reference model is 2D, whereas the travelling slice model degenerates in a simple 1D model. Three different casted shapes were investigated, rounds with diameters of 200 mm, 850 mm, and 1200 mm, spanning from traditional to only recently adopted product diameter sizes. To properly test the validity of the travelling slice model, other casting speeds were considered, even outside the industrial range. Results demonstrate the advantage of using the travelling slice, particularly the much lower computational cost without sacrificing precision, even at low casting speed and large dimensions. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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16 pages, 7096 KiB

Open AccessArticle

Experimental and Numerical Investigation of Hot Extruded Inconel 718

by Stefano Bacchetti, Michele A. Coppola, Francesco De Bona, Alex Lanzutti, Pierpaolo Miotti, Enrico Salvati and Francesco Sordetti

Metals 2023, 13(6), 1129; https://doi.org/10.3390/met13061129 - 16 Jun 2023

Viewed by 1891

Abstract

Inconel 718 is a widely used superalloy, due to its unique corrosion resistance and mechanical strength properties at very high temperatures. Hot metal extrusion is the most widely used forming technique, if the manufacturing of slender components is required. As the current scientific literature does not comprehensively cover the fundamental aspects related to the process–structure relationships, in the present work, a combined numerical and experimental approach is employed. A finite element (FE) model was established to answer three key questions: (1) predicting the required extrusion force at different extrusion speeds; (2) evaluating the influence of the main processing parameters on the formation of surface cracks using the normalized Cockcroft Latham’s (nCL) damage criterion; and (3) quantitatively assessing the amount of recrystallized microstructure through Avrami’s equation. For the sake of modeling validation, several experimental investigations were carried out under different processing conditions. Particularly, it was found that the higher the initial temperature of the billet, the lower the extrusion force, although a trade-off must be sought to avoid the formation of surface cracks occurring at excessive temperatures, while limiting the required extrusion payload. The extrusion speed also plays a relevant role. Similarly to the role of the temperature, an optimal extrusion speed value must be identified to minimize the possibility of surface crack formation (high speeds) and to minimize the melting of intergranular niobium carbides (low speeds). Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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17 pages, 629 KiB

Open AccessArticle

Numerical Simulation of Low-Pressure Carburizing and Gas Quenching for Pyrowear 53 Steel

by Bartosz Iżowski, Artur Wojtyczka and Maciej Motyka

Metals 2023, 13(2), 371; https://doi.org/10.3390/met13020371 - 12 Feb 2023

Cited by 3 | Viewed by 2288

Abstract

The hardness and phase composition are, among other things, the critical material properties considered in the quality control of aerospace gears made from Pyrowear 53 steel after high-pressure gas quenching. The low availability of data on and applications of such demanding structures justify investigating the choice of the material and the need to improve its manufacturability. In this study, computational finite-element analyses of low-pressure carburizing followed by oil and gas quenching of Pyrowear 53 steel were undertaken, the objective of which was to examine the influence of the process parameters on the materials’ final phase composition and hardness. The material input was prepared using JMatPro. The properties computed by the CALPHAD method were calibrated by the values obtained from physical experiments. The heat transfer coefficient was regarded as an objective variable to be optimized. A 3D model of the Standard Navy C-ring specimen was utilized to predict the phase composition after the high-pressure gas quenching of the steel and the hardness at the final stage. These two parameters are considered good indicators of the actual process parameters and are used in the industry. The results of the simulation, e.g., optimized heat transfer coefficients, cooling curves, and hardness and phase composition, are presented and compared with experimental values. The accuracy of the simulation was validated, and a good correlation of the data was found, which demonstrates the quality of the input data and setup of the numerical procedure. A computational approach to heat treatment processes’ design could contribute to accelerating new procedures’ implementation and lowering the development costs. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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26 pages, 11673 KiB

Open AccessArticle

Understanding Uncertainty in Microstructure Evolution and Constitutive Properties in Additive Process Modeling

by Matthew Rolchigo, Robert Carson and James Belak

Metals 2022, 12(2), 324; https://doi.org/10.3390/met12020324 - 12 Feb 2022

Cited by 8 | Viewed by 2312

Abstract

Coupled process–microstructure–property modeling, and understanding the sources of uncertainty and their propagation toward error in part property prediction, are key steps toward full utilization of additive manufacturing (AM) for predictable quality part development. The OpenFOAM model for process conditions, the ExaCA model for as-solidified grain structure, and the ExaConstit model for constitutive mechanical properties are used as part of the ExaAM modeling framework to examine a few of the various sources of uncertainty in the modeling workflow. In addition to “random” uncertainty (due to random number generation in the orientations and locations of grains present), the heterogeneous nucleation density

N_{0}

and the mean substrate grain spacing

S_{0}

are varied to examine their impact of grain area development as a function of build height in the simulated microstructure. While mean grain area after 1 mm of build is found to be sensitive to

N_{0}

and

S_{0}

, particularly at small

N_{0}

and large

S_{0}

(despite some convergence toward similar values), the resulting grain shapes and overall textures develop in a reasonably similar manner. As a result of these similar textures, ExaConstit simulation using ExaCA representative volume elements (RVEs) from various permutations of

N_{0}

S_{0}

, and location within the build resulted in similar yield stress, stress–strain curve shape, and stress triaxiality distributions. It is concluded that for this particular material and scan pattern, 15 layers is sufficient for ExaCA texture and ExaConstit predicted properties to become relatively independent of additional layer simulation, provided that reasonable estimates for

N_{0}

and

S_{0}

are used. However, additional layers of ExaCA will need to be run to obtain mean grain areas independent of build height and baseplate structure. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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23 pages, 4148 KiB

Open AccessArticle

Dynamic Simulations of Manufacturing Processes: Hybrid-Evolving Technique

by Amir M. Horr and Johannes Kronsteiner

Metals 2021, 11(12), 1884; https://doi.org/10.3390/met11121884 - 23 Nov 2021

Cited by 4 | Viewed by 2119

Abstract

Hybrid physical-data-driven modeling techniques have steadily been developed to address the multi-scale and multi-physical aspects of dynamic process simulations. The analytical and computational features of a new hybrid-evolving technique for these processes are elaborated herein and its industrial applications are highlighted. The authentication of this multi-physical and multi-scale framework is carried out by developing an integrated simulation environment where multiple solver technologies are employed to create a reliable industrial-oriented simulation framework. The goal of this integrated simulation framework is to increase the predictive power of material and process simulations at the industrial scale. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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14 pages, 4266 KiB

Open AccessArticle

Mathematical Modelling of Isothermal Decomposition of Austenite in Steel

by Božo Smoljan, Dario Iljkić, Sunčana Smokvina Hanza and Krunoslav Hajdek

Metals 2021, 11(8), 1292; https://doi.org/10.3390/met11081292 - 16 Aug 2021

Cited by 2 | Viewed by 2369

Abstract

The main goal of this paper is mathematical modelling and computer simulation of isothermal decomposition of austenite in steel. Mathematical modelling and computer simulation of isothermal decomposition of austenite nowadays is becoming an indispensable tool for the prediction of isothermal heat treatment results of steel. Besides that, the prediction of isothermal decomposition of austenite can be applied for understanding, optimization and control of microstructure composition and mechanical properties of steel. Isothermal decomposition of austenite is physically one of the most complex engineering processes. In this paper, methods for setting the kinetic expressions for prediction of isothermal decomposition of austenite into ferrite, pearlite or bainite were proposed. After that, based on the chemical composition of hypoeutectoid steels, the quantification of the parameters involved in kinetic expressions was performed. The established kinetic equations were applied in the prediction of microstructure composition of hypoeutectoid steels. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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17 pages, 6752 KiB

Open AccessArticle

Mathematical Modeling of Induction Heating of Waveguide Path Assemblies during Induction Soldering

by Vadim Tynchenko, Sergei Kurashkin, Valeriya Tynchenko, Vladimir Bukhtoyarov, Vladislav Kukartsev, Roman Sergienko, Viktor Kukartsev and Kirill Bashmur

Metals 2021, 11(5), 697; https://doi.org/10.3390/met11050697 - 24 Apr 2021

Cited by 14 | Viewed by 2174

Abstract

The waveguides used in spacecraft antenna feeders are often assembled using external couplers or flanges subject to further welding or soldering. Making permanent joints by means of induction heating has proven to be the best solution in this context. However, several physical phenomena observed in the heating zone complicate any effort to control the process of making a permanent joint by induction heating; these phenomena include flux evaporation and changes in the emissivity of the material. These processes make it difficult to measure the temperature of the heating zone by means of contactless temperature sensors. Meanwhile, contact sensors are not an option due to the high requirements regarding surface quality. Besides, such sensors take a large amount of time and human involvement to install. Thus, it is a relevant undertaking to develop mathematical models for each waveguide assembly component as well as for the entire waveguide assembly. The proposed mathematical models have been tested by experiments in kind, which have shown a great degree of consistency between model-derived estimates and experimental data. The paper also shows how to use the proposed models to test and calibrate the process of making an aluminum-alloy rectangular tube flange waveguide by induction soldering. The Russian software, SimInTech, was used in this research as the modeling environment. The approach proposed herein can significantly lower the labor and material costs of calibrating and testing the process of the induction soldering of waveguides, whether the goal is to adjust the existing process or to implement a new configuration that uses different dimensions or materials. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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16 pages, 8261 KiB

Open AccessArticle

Warpage Analysis and Control of Thin-Walled Structures Manufactured by Laser Powder Bed Fusion

by Xufei Lu, Michele Chiumenti, Miguel Cervera, Hua Tan, Xin Lin and Song Wang

Metals 2021, 11(5), 686; https://doi.org/10.3390/met11050686 - 22 Apr 2021

Cited by 27 | Viewed by 4582

Abstract

Thin-walled structures are of great interest because of their use as lightweight components in aeronautical and aerospace engineering. The fabrication of these components by additive manufacturing (AM) often produces undesired warpage because of the thermal stresses induced by the manufacturing process and the components’ reduced structural stiffness. The objective of this study is to analyze the distortion of several thin-walled components fabricated by Laser Powder Bed Fusion (LPBF). Experiments are performed to investigate the sensitivity of the warpage of thin-walled structures fabricated by LPBF to different design parameters such as the wall thickness and the component height in several open and closed shapes. A 3D-scanner is used to measure the residual distortions in terms of the out-of-plane displacement. Moreover, an in-house finite element software is firstly calibrated and then used to enhance the original design in order to minimize the warpage induced by the LPBF printing process. The outcome of this shows that open geometries are more prone to warping than closed ones, as well as how vertical stiffeners can mitigate component warpage by increasing stiffness. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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12 pages, 5495 KiB

Open AccessFeature PaperArticle

Deep Learning Sequence Methods in Multiphysics Modeling of Steel Solidification

by Seid Koric and Diab W. Abueidda

Metals 2021, 11(3), 494; https://doi.org/10.3390/met11030494 - 17 Mar 2021

Cited by 15 | Viewed by 3212

Abstract

The solidifying steel follows highly nonlinear thermo-mechanical behavior depending on the loading history, temperature, and metallurgical phase fraction calculations (liquid, ferrite, and austenite). Numerical modeling with a computationally challenging multiphysics approach is used on high-performance computing to generate sufficient training and testing data for subsequent deep learning. We have demonstrated how the innovative sequence deep learning methods can learn from multiphysics modeling data of a solidifying slice traveling in a continuous caster and correctly and instantly capture the complex history and temperature-dependent phenomenon in test data samples never seen by the deep learning networks. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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14 pages, 3421 KiB

Open AccessArticle

CFD Simulation Based Investigation of Cavitation Dynamics during High Intensity Ultrasonic Treatment of A356

by Eric Riedel, Niklas Bergedieck and Stefan Scharf

Metals 2020, 10(11), 1529; https://doi.org/10.3390/met10111529 - 18 Nov 2020

Cited by 3 | Viewed by 3015

Abstract

Ultrasonic treatment (UST) and its effects, primarily cavitation and acoustic streaming, are useful for a high range of industrial applications, e.g., welding, filtering, cleaning or emulsification. In the metallurgy and foundry industry, UST can be used to modify a material’s microstructure by treating metal in the liquid or semi-solid state. Cavitation (formation, pulsating growth and implosion of tiny bubbles) and its shock waves, released during the implosion of the cavitation bubbles, are able to break forming structures and thus refine them. In this context, especially aluminium alloys are in the focus of the investigations. Aluminium alloys, e.g., A356, have a significantly wide range of industrial applications in automotive, aerospace and machine engineering, and UST is an effective and comparatively clean technology for its treatment. In recent years, the efforts for simulating the complex mechanisms of UST are increasing, and approaches for computing the complex cavitation dynamics below the radiator during high intensity ultrasonic treatment have come up. In this study, the capabilities of the established CFD simulation tool FLOW-3D to simulate the formation and dynamics of acoustic cavitation in aluminium A356 are investigated. The achieved results demonstrate the basic capability of the software to calculate the above-mentioned effects. Thus, the investigated software provides a solid basis for further development and integration of numerical models into an established software environment and could promote the integration of the simulation of UST in industry. Full article

(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)

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