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Gleeble Systems: Physical Simulation Technology

Gleeble Systems: Physical Simulation Technology. Todd A. Bonesteel. Dynamic Systems Inc. Poestenkill, NY 12140 U.S.A. Outline. History of DSI Fundamentals of Physical Simulation Development of Gleeble Physical Simulators

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Gleeble Systems: Physical Simulation Technology

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  1. Gleeble Systems: Physical Simulation Technology Todd A. Bonesteel Dynamic Systems Inc. Poestenkill, NY 12140 U.S.A.

  2. Outline • History of DSI • Fundamentals of Physical Simulation • Development of Gleeble Physical Simulators • Applications of Physical Simulation Technologies to Metal Industries

  3. History of DSI • Gleeble developed late 1940s to Study Weld HAZ Phenomena • DSI Founded 1957 • Pioneers of Physical Simulation • First Export - Society de France - June 1962

  4. Fundamentals of Physical Simulation • Furnace Heating • Induction Heating • Bulk Heating

  5. Laboratory Heating

  6. Gleeble Test Principle

  7. Axial Thermal Gradient Control

  8. Axial Thermal Gradient Control • Steep Thermal Gradient Generation

  9. Axial Thermal Gradient Control • Flat Thermal Gradient Generation

  10. Gleeble Specimen Thermal Profile • Axial Thermal Gradient Control

  11. 60 60 Specimen size: 10mm diameter 50 50 Helium Carbon Steel 40 40 Argon Surface to Center Temp Difference (°C) 30 30 Carbon Steel Vacuum 20 20 Carbon Steel Argon Stainless Steel 10 10 With Flexible Thermal Sleeve 0 0 800 900 1000 1100 1200 1300 Test Temperature (°C) Gleeble Specimen Thermal Profile • Radial Thermal Gradient Control

  12. Development of Gleeble Thermal Mechanical Simulators • Hydrawedge System • Hot Torsion System: HTS-50 • Multi-Axis Deformation Simulator: MAXStrainSystem • HDS-V40 SimCast System

  13. Series 3 Digital Control System:The Gleeble 3500 Since 1995

  14. Gleeble 3500 Specifications • Max. speed: 1,000mm/s • Loading capacity: 10 metric tons in tension and compression • Max. heating rate: 10,000C/sec

  15. Digital Control System:The Hydrawedge System Since 1990

  16. Mechanism of the Hydrawedge System Digital Control System:The Hydrawedge System Load cell Anvils Yoke Stop Jaw transducer Specimen loader

  17. Digital Control System:The Hydrawedge System • Separate yet Synchronized Control of Strain and Strain Rate • No Over-Travel at A High Speed • Multiple Compression at Different Values of Strain, Strain Rate and Temperature

  18. Digital Control System:The Hot Torsion System / HTS Since 1996

  19. Typical Torsion Test Setup Digital Control System:The Hot Torsion System / HTS Resistance Heating Furnace Specimn Floating/ Fixed End Rotation End

  20. Digital Control System:The Hot Torsion System / HTS • Instant Speed-up: < 5msec to reach 1,000 rpm • Free Coupler for Minimal Strain Error during Acceleration and Free Unloading • Environment Control: Inert gas or vacuum • In-situ Quenching

  21. Digital Control System:The Hot Torsion System / HTS • Servo Hydraulic Control System • Combined Torsion and Tension/Compression Control during Torsion • Rapid Resistance Heating and Cooling • Thermocouple or Pyrometer Control • Uniform Temp. within Gauge Length

  22. Why Physical Simulation

  23. Gleeble Applications on Metals Handbook

  24. Applications of Physical Simulation Technologies • Basic Materials Studies • Materials Testing • Metallurgical Process Simulation

  25. Basic Materials Studies • Phase Transformation / Precipitation • Oxidation / Decarbonization / Diffusion • Liquid Embrittlement • Constitutional Liquation • Crack Susceptibility • Liquid Metal Wetability • Liquid and Solid Metal Thermal Expansion / Contraction

  26. Basic Materials Studies • Melting /Solidification • Superplasticity • Work Hardening / Softening • Recrystallization / Recovery • Precipitation • Ultra-Fine Grain Materials • Nanometer Materials

  27. Materials Testing • Hot Ductility / Hot Workability / SICO • Uniaxial / Plane Strain Compression • Dynamic and Static CCT / CHT / TTT • Weldability / NST / NDT / BTR / RDR • Thermal and/or Mechanical Fatigue • Superplasticity / Elongation • Elastic Modulus / Yield Stress / UTS

  28. Materials Testing • Creep / Stress Rupture • Plane Strain Fracture Toughness / CTOD • ......

  29. Process Simulation • Casting / Foundry • Semi-Solid Processing • TMCP (Rolling, Forging and Extrusion) • Welding: HAZ cycling, Weld metal, Laser welding, Electron beam welding, Upset butt welding, Friction stir welding ... • Diffusion Bonding

  30. Process Simulation • Heat Treatment (Annealing, Normalizing, Quenching, Tempering, ...) • Strip Annealing • Powder Metallurgy / Sintering / HIPping • Synthesis (SHS) • ....

  31. Con-Casting Process Simulation • Slab Casting Process Simulation

  32. Con-Casting Process Simulation • Castability Map Development

  33. Con-Casting Process Simulation • Castability Map Development

  34. Con-Casting Process Simulation • Hot Ductility Test

  35. Con-Casting Process Simulation • Castability Map Development

  36. Con-Casting Process Simulation • Castability Map Development Optimal cooling rate ( C ) for an aluminum killed steel to produce crack free billets

  37. Graphite Foil Specimen ISO -T TM Anvils Anvil Base Anvil Base Temp Free Span Schematic Setup of Isothermal Flow Stress Testing Using the ISO - TTM Anvils Uniaxial Compression Testing • ISO-T TM Anvils

  38. Uniaxial Compression Testing • ISO-T TM Anvils

  39. Uniaxial Compression Testing • Uniform Deformation with ISO-T TM Anvils 10 mm dia. specimen after 60% reduction at 1000oC (x100)

  40. Hot Workability Test Technique • Hot Ductility Test

  41. Hot Workability Test Technique • Effect of Thermal Gradient on Material Strength

  42. Hot Workability Test Technique • SICOTM Procedure

  43. Hot Workability Test Technique • SICOTM Procedure

  44. Hot Workability Test Technique • SICOTM Procedure Aluminum Alloy Austenitic Alloy Ni-base Superalloy 10 mm dia. SICO bar

  45. Hot Workability Test Technique • Critical Strain in SICO Procedure • 1.  2.

  46. Hot Workability Test Technique • SICOTM Procedure vs. Hot Ductility Test

  47. Thermomechanical Processing • Optimization of Thermomechanical Processes

  48. Thermomechanical Processing • Optimization of Thermomechanical Processes

  49. Thermomechanical Processing • Optimization of Thermomechanical Processes

  50. (a) Extraction of the LBT specimen from welded assembly (b) LBT specimen (c) Bent LBT specimen showing area of examination Weld Metal Crack Susceptibility Study • Conventional LBT Procedure

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