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HPC Midlands - University of Leicester and Tata Steel HPC Collaboration
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HPC Midlands - University of Leicester and Tata Steel HPC Collaboration

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Professor Hongbiao Dong from the University of Leicester and Shuwen Wen, Principal Scientist at Tata Steel, describe their collaboration using HPC to model the welding process. For more information, …

Professor Hongbiao Dong from the University of Leicester and Shuwen Wen, Principal Scientist at Tata Steel, describe their collaboration using HPC to model the welding process. For more information, please see http://hpc-midlands.ac.uk

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  • 1. HPC Midlands Launch Event March 20, 2013Leicester – Tata Steel collaboration Hongbiao Dong1, Shuwen Wen2 1. University of Leicester 2. Tata Steel
  • 2. Tata Steel: a multinational steel company, subsidiary of Tata Fortune 500 company Top 10 global steelmaker: production capacity 28 Mt/a Manufacturing operations in 26 countries Commercial presence in Jamshedpur over 50 countries India 80 000 employees Listed in Mumbai Port Talbot UK Ijmuiden The Netherlands 2
  • 3. Locations Tata Steel Group RD&T TTC Jamshedpur India R&D STC IJTC AEGTTC: Teesside Technology CentreSTC: Swinden Technology Centre (Rotherham) UK total 350 peopleAEG: Automotive Engineering Group (Coventry) IJmuiden 445 peopleIJTC: IJmuiden Technology Centre India total 450 people 3
  • 4. Tata Steel R, D&T Swinden Technology Centre (STC)• Processes, Products and Applications• Departments in: • Iron making (TTC & IJTC) • Steel making & continuous casting • Steel Metallurgy • Iron making • Long Product Rolling • Rolling Metal Strip • Industrial & Construction • Environment Rotherham S60 3AR, UK 4
  • 5. 5
  • 6. Top 200 universities worldwide*Department of Engineering
  • 7. Mechanics of Materials Group at Leicester• At the interface between Mechanical Engineering and Materials Engineering.• Research by integrating experimental and computational technologies.• Our computational work benefits from ALICE and East Midlands HPC – ALICE: a new High Performance Computing (HPC) cluster at Leicester
  • 8. Mechanics of Materials Group at Leicester• At the interface between Mechanical Engineering and Materials Engineering.• Research by integrating experimental and computational technologies.• Our computational work benefits from ALICE and East Midlands HPC – ALICE: a new High Performance Computing (HPC) cluster at Leicester • Multi-scale, Multi-physics Materials Process Modelling • Casting, Welding, Heat Treatment • Microstructure Evolution during Processing and In-use of High Temperature Materials
  • 9. What Can Materials Process Modelling Do ? To visualize process routes What are the physical processes occurring during processing (casting, welding, heat treatment and coating) ? What are the optimum dimensions and geometry of components with regard to processing? Can numerical modelling be used to answer the above questions? Can we move away from empirical choices of casting, welding /HT/coating processes to one which is designed and optimised? 9
  • 10. Multi-scale Multi-physical Nature of Materials Processing cathode (-) radiation filler wire (electrode) crystal growth, (b) element segregation Plasma gas heat flux free surface solute diffusion drag arc pressure latent heat 300 m anode (+) marangoni grain boundary 1nm segregation JB stress melting/solidification heat conduction elastic/plastic- interface deformation weld pool workpiece A workpiece B 3nm intermetallic (c) structure defects (a) Energetics and kinetics of interface, bonding Crystal A Crystal B /Melt strength10 (d)
  • 11. scale (time/length) modelsquantum(10-12s / 10-10 to 10-9m) ab-initio quantum mechanical thermodynamic data; Models force fields, including H-alloy interaction; atomic arrangement at interfaces interfacial properties Inter-atomic potentialsclassical molecular diffusion of hydrogen,(10-7s / 10-9 to 10- dynamics structural cohesive zone model8m) integrity, interface structure thermodynamic properties of chemistry; solid-liquid & solid-solid crystal orientation; stress hot cracking interfaces microstructure & + chemistry, hydrogennano-micro phase field crystal thermodynamics of phase field embrittlement(10-3s / 10-9 to 10-3m) fracture/ defect growth, residual stress, dendrite kinetics; latent heat; enthalpy change; grain solidification interface; structure; local chemistry; thermal microscopic morphology field and local gradients grain structure Computationalgrain model alloy-specific thermo-dynamics(10-3 to 101s / 10-4 to 10- thermodynamics &2m) kinetics boundary conditions; solidification fronts; mushy chemistry; flow pattern; thermal field zone permeabilitymacro computational fluid dynamics(102s / 10-3 to 10-1m) finite element analysis
  • 12. Macro-scale: In-situ Observation of Internal Flow in Weld Pool Lincoln remotely Powertec 231C welding controlled metal machine active gas 10mm thickness (MAG) steel plate welding headBeamSource Detector Return current Insulating plate Beamline sample stage 12
  • 13. Lincoln Powertec 231C welding machine 10mm thickness steel plate welding headBeamSource Detector Return current Insulating plate Beamline sample stage 13
  • 14. we ma 10mm thicknesssingle streamlines of flow steel plate welding head electrode Beam (a) advancing Source Det melt pool Return current flow trace Insulating plate over 0.1 s Beamline sample stage solidified joint (a) over 50 mini seconds (b) electrode advancing (b) over 120 mini melt pool seconds (X-ray radiography) flow trace over 0.23 s solidified joint 14
  • 15. Modelling work to analyse the internal flow• The quantitative analysis of the fluid flow has been proven difficult, although progress has been made in analysing the velocity data.• This is because different forces (plasma and arc pressure, Marangoni and Lorentz forces) act on fluid dynamics in weld pool. With Lorentz force driven flow (S=0%) Without Lorentz force driven flow (S=0%) 15
  • 16. 16
  • 17. Solid-liquid interface fluctuation System: Pure Fe (100)[010] plane Atoms: 43,200 System size: 17.545 1.7545 17.545 nm Time: 1ns, dt=5fs
  • 18. Potential Impact• Being able to predict and control properties using HPC during welding, and hence to produce welds with radically improved properties will certainly help improve the productivity of pipeline products and the integrity of the constructed gas and oil pipelines by using new alloys in conjunction with advanced technologies.• The technique has been taking forward by industry to develop advanced welding technology for new welded pipelines, the construction time is usually 2 to 3 years in an European leading steel- making industry, during which welding development is a major issue.• The overall cost involved in the development is several million Euros. When these pipeline products are in use, the cost for the construction of a pipeline is often up to several billion Euros and the integrity of the pipeline has huge implications for the local energy supply and hence economic prosperity. 18
  • 19. With the advances in HPC & processing modelling, Changes can be made in manufacturing?
  • 20. AcknowledgementEPSRC, the European Commission, the Royal Society , Tata Steel, Rolls-Royce, TWI, for research fundingColleagues and PhD students at University of Leicester, Loughborough University for providing information in this presentation