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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

Gleeble Systems: Physical Simulation Technology

Todd A. Bonesteel

Dynamic Systems Inc.

Poestenkill, NY 12140

U.S.A.

outline
Outline
  • History of DSI
  • Fundamentals of Physical Simulation
  • Development of Gleeble Physical Simulators
  • Applications of Physical Simulation Technologies to Metal Industries
history of dsi
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
fundamentals of physical simulation
Fundamentals of Physical Simulation
  • Furnace Heating
  • Induction Heating
  • Bulk Heating
axial thermal gradient control8
Axial Thermal Gradient Control
  • Steep Thermal Gradient Generation
axial thermal gradient control9
Axial Thermal Gradient Control
  • Flat Thermal Gradient Generation
gleeble specimen thermal profile
Gleeble Specimen Thermal Profile
  • Axial Thermal Gradient Control
gleeble specimen thermal profile11

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
development of gleeble thermal mechanical simulators
Development of Gleeble Thermal Mechanical Simulators
  • Hydrawedge System
  • Hot Torsion System: HTS-50
  • Multi-Axis Deformation Simulator: MAXStrainSystem
  • HDS-V40 SimCast System
gleeble 3500 specifications
Gleeble 3500 Specifications
  • Max. speed: 1,000mm/s
  • Loading capacity: 10 metric tons in tension and compression
  • Max. heating rate: 10,000C/sec
digital control system the hydrawedge system17
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
digital control system the hot torsion system hts19
Typical Torsion Test SetupDigital Control System:The Hot Torsion System / HTS

Resistance Heating Furnace

Specimn

Floating/

Fixed End

Rotation End

digital control system the hot torsion system hts20
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
digital control system the hot torsion system hts21
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
applications of physical simulation technologies
Applications of Physical Simulation Technologies
  • Basic Materials Studies
  • Materials Testing
  • Metallurgical Process Simulation
basic materials studies
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
basic materials studies26
Basic Materials Studies
  • Melting /Solidification
  • Superplasticity
  • Work Hardening / Softening
  • Recrystallization / Recovery
  • Precipitation
  • Ultra-Fine Grain Materials
  • Nanometer Materials
materials testing
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
materials testing28
Materials Testing
  • Creep / Stress Rupture
  • Plane Strain Fracture Toughness / CTOD
  • ......
process simulation
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
process simulation30
Process Simulation
  • Heat Treatment (Annealing, Normalizing, Quenching, Tempering, ...)
  • Strip Annealing
  • Powder Metallurgy / Sintering / HIPping
  • Synthesis (SHS)
  • ....
con casting process simulation
Con-Casting Process Simulation
  • Slab Casting Process Simulation
con casting process simulation32
Con-Casting Process Simulation
  • Castability Map Development
con casting process simulation33
Con-Casting Process Simulation
  • Castability Map Development
con casting process simulation35
Con-Casting Process Simulation
  • Castability Map Development
con casting process simulation36
Con-Casting Process Simulation
  • Castability Map Development

Optimal cooling rate ( C ) for an aluminum killed steel to produce crack free billets

uniaxial compression testing

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
uniaxial compression testing39
Uniaxial Compression Testing
  • Uniform Deformation with ISO-T TM Anvils

10 mm dia. specimen after 60% reduction at 1000oC (x100)

hot workability test technique41
Hot Workability Test Technique
  • Effect of Thermal Gradient on Material Strength
hot workability test technique44
Hot Workability Test Technique
  • SICOTM Procedure

Aluminum Alloy

Austenitic Alloy

Ni-base Superalloy

10 mm dia. SICO bar

hot workability test technique45
Hot Workability Test Technique
  • Critical Strain in SICO Procedure
  • 1.  2.
hot workability test technique46
Hot Workability Test Technique
  • SICOTM Procedure vs. Hot Ductility Test
thermomechanical processing
Thermomechanical Processing
  • Optimization of Thermomechanical Processes
thermomechanical processing48
Thermomechanical Processing
  • Optimization of Thermomechanical Processes
thermomechanical processing49
Thermomechanical Processing
  • Optimization of Thermomechanical Processes
weld metal crack susceptibility study

(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
welding simulation
Welding Simulation
  • Crack Susceptibility of Weld Metals

No cracks, 1050C, 0.41, 3/s, Bottom layer

Some cracks, 1050C, 0.41, 3/s, Top layer

Many cracks, 1050C, 0.41, 3/s, Bottom layer

weld metal crack susceptibility study53

Critical Strains for Top and Bottom Layers

of Multi-pass Weld Metal

0.6

Crack from Bottom Layer

Crack from Top Layer

0.5

Critical Strains

0.4

for Bottom Layer

0.3

Hoop Strain, (ln (D/d)

Critical Strains

0.2

for Top Layer

0.1

0.0

900

950

1000

1050

1100

1150

1200

Temperature (°C)

Weld Metal Crack Susceptibility Study
  • Using SICOTM Procedure
weld metal crack susceptibility study54

C

a5

a6

*

b6

b5

(5)

(4)

(6)

a5

(3)

a4

b4

b5

a6

a3

b6

b3

(1)

(2)

a1

a2

b1

b2

Weld Metal Crack Susceptibility Study
  • Micromechanism of Microfissuring
weld metal crack susceptibility study55
Weld Metal Crack Susceptibility Study
  • Application of the SICOTM Procedure

Compositions (wt%) of the Four Electrodes Tested

weld metal crack susceptibility study56
Weld Metal Crack Susceptibility Study
  • Nil-Strength Temperature Measurement

Nil-Strength Temperatures (oC) of Four Electrodes

weld metal crack susceptibility study57

0.8

crack: 20.32Nb

no crack: 20.32.Nb

crack: 625KS

0.6

no crack: 625KS

0.4

Critical Strain, ln (D/d)

20.32Nb

0.2

625KS

0.0

1000

1100

1200

1300

Temperature (°C)

Weld Metal Crack Susceptibility Study
  • Application of the SICOTM Procedure
weld metal crack susceptibility study58

Metrode: 1- 625KS, 2- NCM12 and 3- NIM721

0.5

Crack-1,

No Crack-1

Crack-2,

No Crack-2

0.4

Crack-3,

No Crack-3

NCM12

625KS

Heating rate: 150°C/s

0.3

Strain rate: 3/s

Critical Strain, ln(D/d)

0.2

NIM721

0.1

0.0

1000

1100

1200

1300

Temperature (°C)

Weld Metal Crack Susceptibility Study
  • Application of the SICOTM Procedure
weldability test technique
Weldability Test Technique
  • HAZ Hot Ductility Test
weldability test technique60
Weldability Test Technique
  • HAZ Hot Ductility Test
fracture criterion

0.5

SICO Strain

Tensile Strain

0.4

0.3

Fracture Strain

0.2

0.1

0.0

900

1000

1100

1200

Temperature (°C)

Fracture Criterion
  • Strain Fracture Criterion
fracture criterion62
Fracture Criterion
  • Cockcroft and Latham’s Plastic Work Fracture Criterion
  • Modified Plastic Work Fracture Criterion
hot workability

Comparison of Fracture Limit to Reduction of Area

8

100

7

80

6

5

60

4

R.A.

Reduction of Area (%)

Fracture Limit

Limit

40

3

60°C/mm

2

20

1

0

0

800

1000

1200

1400

Temperature (°C)

Hot Workability
  • Fracture Limit and Reduction of Area
hot working process simulation

Specimen Height (mm)

7

6

5

4

1000

1. Correct Strain & Strain

800

3. Correct Strain Rate

Rate with HYDRAWEDGE

but Over-traveled Strain

1

with Normal Hydraulic

600

Systems

3

Stroke Rate (mm/s)

400

2

2. Correct Strain but Incorrect

200

Strain Rate with Normal

Hydraulic Systems

0

0

1

2

3

4

5

Deformation Time (millisecond)

Hot Working Process Simulation
  • Stopping Response in High Speed Compression (Hit 2)
hot working process simulation65

Specimen Height (mm)

5

5

5

4

3

2

1

1000

3. Correct Strain Rate

but Over-traveled Strain

800

with Normal Hydraulic

System

600

Start of Deformation

Stroke Rate (mm/s)

400

2. Correct Strain but Incorrect

1. Correct Strain & Strain

200

Strain Rate with Normal

Rate with HYDRAWEDGE

Hydraulic Systems

0

-2

-1

0

1

2

3

4

Deformation Time (millisecond)

Hot Working Process Simulation
  • Stopping Response in High Speed Compression (Hit 3)
hot working process simulation66
Hot Working Process Simulation
  • Hydrawedge System Performance
hot working process simulation67
Hot Working Process Simulation
  • Hydrawedge System Performance
hot working process simulation68

-100

A Plain Carbon Steel

-80

-60

-40

True Stress(MPa)

-20

1192°C

1164°C

1220°C

0

23/s

44/s

16/s

0.0

-0.2

-0.4

-0.6

-0.8

-1.0

True Strain

Hot Working Process Simulation
  • Three-Hit Test of Hydrawedge Application
hot working process simulation69
Hot Working Process Simulation
  • Six-Pass Hot Rolling Process Simulation
cct ttt laser welding
CCT / TTT / Laser Welding
  • ISO-QTM Quenching Technique
cct ttt studies
CCT / TTT Studies
  • Effect of Deformation on Phase Transformation
laser measurement

Laser

Transmitter

T.C.

Moving

Load

Cell

Jaw

Vacuum Chamber

Laser

Receiver

Schematic layout of a laser system during hot tensile testing

Laser Measurement
  • Patented Laser Tracking System
cct ttt for strip specimen

50 mm

Strip Specimen

Quartz Rod

6 mm

13 mm

LVDT C-Gauge Dilatometry

50 mm

Strip Specimen

6 mm

22 mm

Laser Dilatometry

CCT Dilatometry Measurement for Strip Specimens

CCT / TTT for Strip Specimen
  • Isothermal Plane for CCT
strip annealing simulation

electric current

50mm

20mm

1-2 mm

25mm

20mm

250mm

Strip Annealing Simulation
  • Patented SISR Technique for Deep Drawing Ability Test Specimens
strip annealing simulation75
Strip Annealing Simulation
  • Patented SISR Technique for Making Deep Drawing Ability Test Specimens
strip annealing simulation76
Strip Annealing Simulation
  • Specimen Heating Using Patented SISR Technique
strip annealing process simulation
Strip Annealing Process Simulation
  • 1mm x 50mm x 200mm Strip Specimen
strip annealing process simulation78
Strip Annealing Process Simulation
  • Strip Annealing Jaw System
gleeble scrip language
Gleeble Scrip Language
  • Pulse Quenching Techniques
visit gleeble web page
Visit Gleeble Web Page

W W W.GLEEBLE.COM

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