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Friction stir welding (FSW) is a manufacturing process that many industries have adopted to join metals in a solid state, resulting in unique properties. However, studying aspects like temperature distribution, stress distribution, and material flow experimentally is challenging due to severe plastic deformation in the weld zone. Therefore, numerical methods are utilized to investigate these parameters and gain a better understanding of the FSW process. Numerical models are employed to simulate material flow, temperature distribution, and stress state during welding. This allows for the identification of potential defect-prone zones. This paper presents a comprehensive review of research activities and advancements in numerical analysis techniques specifically designed for friction stir welding, with a focus on their applicability to component manufacturing. The paper begins by examining various types of numerical methods and modeling techniques used in FSW analysis, including finite element analysis, computational fluid dynamics, and other simulation approaches. The advantages and limitations of each method are discussed, providing insights into their suitability for FSW simulations. Furthermore, the paper delves into the crucial variables that play a significant role in the numerical modeling of the FSW process. [ABSTRACT FROM AUTHOR]

Friction Stir Extrusion (FSE), the focus of this research, is a process that has tremendous potential for shaping and improving the mechanical properties of the final product as well as the mechanical alloying. In this study, a cylindrical sample of LM13 aluminum, to which silicon powder is added, is extruded by the penetration of a tool and takes the shape of a tube. The microstructure of the aluminum tube produced is studied using a light microscope. Various tests, including compression and wear tests, are performed to evaluate the wear and mechanical properties of the tubes produced. Additionally, the process is simulated using the finite element method (FEM), and the strain and temperature distributions in the tubes are examined to understand the impact of tool advancing speed better. The strain and temperature are highest on the inner surface, where the tubes meet the tool. Moreover, as the advancing speed increases from 25 to 40 mm/min, the maximum temperature in the tubes increases from 350 to 400 °C. The surface quality of the samples is directly related to the advancing speed, so the surface quality improves as the advancing speed increases. The results obtained from the compression and wear tests show that the compression strength has increased by about 17%, and the wear resistance has improved by about 20%. [ABSTRACT FROM AUTHOR]

An efficient finite element model based on conventional shell elements available in ABAQUS software has been developed for free vibration analysis of FGM monolayer and sandwich flat panels. Applications to sandwich plates with an FGM layer embedded as either a core or face sheets with different through-the-thickness material gradations in the form of power (P-FGM), sigmoid (S-FGM), and exponential (E-FGM) distributions are considered. A user-defined material subroutine UMAT was used to implement functionally graded properties of the constitutive FGM layer. Numerical studies are given for free vibrations of monolayer and sandwich plates subjected to various boundary conditions and with different structural parameters such as span-to-thickness, face sheet-core-face sheet thickness and aspect ratios, and volume fraction index. The studies showed very good agreement between the present results and those existing in the literature that confirmed the accuracy of the developed model at minimal computational costs. This emphasizes the efficiency of the shell-based modeling strategy proposed for the calculations. A series of numerical solutions obtained in the research extends the results of known testing examples and may serve as additional benchmark data for other analysts. [ABSTRACT FROM AUTHOR]

A survey of recent developments in the dynamic analysis of sandwich panels with face sheet-to-core debonding is presented. The finite element method within the ABAQUS™ code is utilized. The emphasis is directed to the procedures used to elaborate linear and nonlinear models and to predict dynamic response of the sandwich panels. Recently developed models are presented, which can be applied for structural health monitoring algorithms of real-scale sandwich panels. First, various popular theories of intact sandwich panels are briefly mentioned and a model is proposed to effectively analyse the modal dynamics of debonded and damaged (due to impact) sandwich panels. The influences of debonding size, form, and location and number of such damage incidents on the modal characteristics of sandwich panels are shown. For nonlinear analysis, models based on implicit and explicit time integration schemes are presented and dynamic responses gained with those models are discussed. Finally, questions related to debonding progression at the face sheet-core interface when dynamic loading continues with time are briefly highlighted. [ABSTRACT FROM AUTHOR]

Modelling and testing of hybrid joints obtained by combination of two simple techniques,i.e.,by application of spot welding and adhesive, is reported. The joints were subjected to uniaxial tension. The experiments were performed for: 1) a pure joining of the parts by spot welding and 2) spot welding–adhesive joining of the structural elements. A new experimental method was elaborated with application of two digital image correlation (DIC) systems. The method allowed for online monitoring of the deformation process of the joined elements with complex shapes. Modelling of the hybrid joints response to mechanical loading was performed by ABAQUS code. Damage process in the adhesive layer was taken into account. The obtained results lead to the conclusion that the strengthening of joints by the application of adhesive significantly improves static strength and energy absorption. The visible degradation process of the adhesive layer which started prior to the maximum value of force carrying the hybrid joint was obtained. [ABSTRACT FROM PUBLISHER]

Highlights: [•] The XFEM and the R&T techniques were exploited in damage analysis of the WC/Co microstructure. [•] Damage propagation analysis was performed with 2-D numerical models. [•] The Gurson–Tvergaard material porosity was used for the description of the Co interface. [•] Traction–Separation and Ductile Damage Criterions were used to model the WC/Co composite damage process. [Copyright &y& Elsevier]

Highlights: [•] FEM-based numerical analyses of road pavement cracking were conducted. [•] 2D model of a pavement layer structure was devised. [•] ANNs were applied to classify pavement condition. [•] Effect of particular bituminous layer parameters on road pavement cracking sensitivity was determined. [ABSTRACT FROM AUTHOR]

This study presents a description of the new technology for producing external or internal layers made of different powders mixed with epoxy resin, which can perform various functions as a protection against impact, erosion, or elevated temperatures as well as provide interlayers during the manufacturing of a ceramic protective barrier by air plasma spraying (APS) on the PMC substrate made of carbon–epoxy. Six types of powders (copper, quartz sand, Al2O3, aluminum, crystalline silica, and microballoon) were used to manufacture (120 °C) different kinds of protective layers (PLs), perfectly joined with the PMCs, in one single autoclave process. The two-layered specimens (2 × 25 × 110 mm) were subjected to a three-point bending (3-PB) displacement-controlled deformation process to determine the critical values of deformations at which the PLs can work safely without being cracked or delaminated. The tests were performed up to the final failure, observing various damage and cracking phenomena. Finally, the numerical simulations were carried out using the representative volume element (RVE) model of the most efforted central parts of the samples to determine the effect of powder grain diameter and resin content on the elastic properties and damage growth of the newly proposed multifunctional PLs. The stress concentrations and damage processes, including cracking and delamination, were analyzed in the whole two-layered system. The best result, in terms of strength during 3-PB testing, was achieved with the PL made of aluminum powder. [ABSTRACT FROM AUTHOR]

In this article we study the deformation of thermo-elastic multi-layered shells, using a Cosserat model. By this direct approach, the shell-like bodies are modeled as deformable surfaces with a triad of rigidly rotating directors assigned to every point. The thermal effects are described with the help of two independent temperature fields. Concerning cylindrical orthotropic layered shells, we establish a general solution procedure for a class of thermal stresses problems. These analytical solutions are compared in some special cases with the corresponding three-dimensional solutions and thus, the thermo-elastic coupling coefficients for shells are identified in terms of the material/geometrical parameters of the layers. Finally, we present a comparison between our theoretical results and the numerical solutions obtained by a finite element analysis of a 3-layered cylindrical shell. [ABSTRACT FROM AUTHOR]

Abstract: The dynamic behavior of partially delaminated at the skin/core interface sandwich plates with flexible cores is studied. The commercial finite element code ABAQUS is used to calculate natural frequencies and mode shapes of the sandwich plates containing a debonding zone. The influence of the debonding size, debonding location and types of debonding on the modal parameters of damaged sandwich plates with various boundary conditions is investigated. The results of dynamic analysis illustrated that they can be useful for analyzing practical problems related to the non-destructive damage detection of partially debonded sandwich plates. [ABSTRACT FROM AUTHOR]

The paper investigates the effect of the biaxial loading on crack deflection/penetration at a bi-material ceramic interface. A biaxially loaded geometry was numerically investigated using Finite Element Analysis in order to determine the energy release rate. The obtained results could be used in conjunction with a fracture criteria at interface for estimating the path of the crack after the interface was reached. [ABSTRACT FROM AUTHOR]

Stress intensity factors for a kinked crack originating at interface of two bonded dissimilar materials subjected to normal tension are found by the finite element method. [ABSTRACT FROM AUTHOR]

In the case of protection of transportation systems, the optimization of the shield is of practical interest to reduce the weight of such components and thus increase the payload or reduce the fuel consumption. As far as metal shields are concerned, some investigations based on numerical simulations showed that a multi-layered configuration made of layers of different metals could be a promising solution to reduce the weight of the shield. However, only a few experimental studies on this subject are available. The aim of this study is therefore to discuss whether or not a monolithic shield can be substituted by a double-layered configuration manufactured from two different metals and if such a configuration can guarantee the same perforation resistance at a lower weight. In order to answer this question, the performance of a ballistic shield constituted of a layer of high-strength steel and a layer of an aluminum alloy impacted by an armor piercing projectile was investigated in experimental tests. Furthermore, an axisymmetric finite element model was developed. The effect of the strain rate hardening parameter C and the thermal softening parameter m of the Johnson–Cook constitutive model was investigated. The numerical model was used to understand the perforation process and the energy dissipation mechanism inside the target. It was found that if the high-strength steel plate is used as a front layer, the specific ballistic energy increases by 54% with respect to the monolithic high-strength steel plate. On the other hand, the specific ballistic energy decreases if the aluminum plate is used as the front layer. [ABSTRACT FROM AUTHOR]

Ultralight sandwich constructions with corrugated channel cores (i.e., periodic fluid-through wavy passages) are envisioned to possess multifunctional attributes: simultaneous load-carrying and heat dissipation via active cooling. Titanium alloy (Ti-6Al-4V) corrugated-channel-cored sandwich panels (3CSPs) with thin face sheets and core webs were fabricated via the technique of selective laser melting (SLM) for enhanced shear resistance relative to other fabrication processes such as vacuum brazing. Four-point bending responses of as-fabricated 3CSP specimens, including bending resistance and initial collapse modes, were experimentally measured. The bending characteristics of the 3CSP structure were further explored using a combined approach of analytical modeling and numerical simulation based on the method of finite elements (FE). Both the analytical and numerical predictions were validated against experimental measurements. Collapse mechanism maps of the 3CSP structure were subsequently constructed using the analytical model, with four collapse modes considered (face-sheet yielding, face-sheet buckling, core yielding, and core buckling), which were used to evaluate how its structural geometry affects its collapse initiation mode. [ABSTRACT FROM AUTHOR]

Adhesive bonding are becoming increasingly important in civil and mechanical engineering, in the field of mobile applications such as aircraft or automotive. Adhesive joints offer many advantages such as low weight, uniform stress distribution, vibration damping properties or the possibility of joining different materials. The paper presents the results of numerical modeling and the use of neural networks in the analysis of dual adhesive single-lap joints subjected to a uniaxial tensile test. The dual adhesive joint was created through the use of adhesives with various parameters in terms of stiffness and strength. In the axis of the overlap, there was a point bonded joint characterized by greater stiffness and strength, and on the outside, there was a bonded joint limited by the edges of the overlap and characterized by lower stiffness and strength. It is an innovative solution for joining technology and the influence of such parameters as the thickness of one of the adherends, the radius of the point bonded joint and the material parameters of both adhesive layers were analyzed. The joint is characterized by a two-stage degradation process, i.e., after the damage of the rigid adhesive, the flexible adhesive ensures the integrity of the entire joint. For numerical modeling, the Finite Element Method (FEM) and cohesive elements was used, which served as input data to an Artificial Neural Network (ANN). The applied approach allowed the impact of individual parameters on the maximum force, initiation energy, and fracture energy to be studied. [ABSTRACT FROM AUTHOR]

One of the fundamental criteria in the design of air structures is to achieve required strength at the highest possible reduction of structure weight w . However, it is necessary to keep the second design parameter i.e. stiffness of the air structural element on the proper level in order to satisfy durability and reliability of aircrafts. This paper presents the application of an integrated system based on artificial neural networks and calculations by the finite element method (FEM) for the optimization of geometry of a thin-walled element of an air structure. The main criterion of optimization was to reduce the structure’s weight w at the lowest possible deformation (high stress level) of the tested object. The objective of the analyses – using artificial neural networks (ANN) – was to investigate the effect of 4 individual variables defining geometry of the model (including: system of ribs and their inclination, system of holes in ribs and side walls) on its deformation and final value of the reduced weight w . Numerical analysis showed that the most important variable is the diameter of holes in the side walls of the model. [ABSTRACT FROM AUTHOR]

Abstract: Analysis and fracture interpretation (using the strain energy density criterion) of Compact Shear specimen for Mode II fracture testing of materials is presented in the paper. Two approaches are used. One is based on singular integral equations for the problem of the interaction of two parallel cracks under Mode II loading corresponding to the loading in the Compact Shear specimen (CS specimen). Approximate analytical formulas for the stress intensity factors at the crack tips are derived. A numerical calculation using Gauss-quadrature formulae for the corresponding integral equations is presented. The influence of geometry of the problem on the stress intensity factors and on the angles of the initial propagation direction of the cracks is investigated. The other approach is Finite Element Method implemented in FRANC2D/L code. Numerical analysis was done for plain strain conditions. Different geometries of the specimen are considered for two models of the CS specimen and compared with results available in the literature. Analytical and FEM calculations are also compared and discussed. [Copyright &y& Elsevier]