Gleeble Systems: Physical Simulation Technology

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
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 SystemThe 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
Digital Control System The Hydrawedge? System

• Mechanism of 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 SystemThe Hot Torsion System /
HTS
Since 1996
19
Digital Control System The Hot Torsion System /
HTS

• Typical Torsion Test Setup

Resistance Heating Furnace
Specimn
Floating/ Fixed End
Rotation End
20
Digital Control SystemThe Hot Torsion System /
HTS

• Instant Speed-up lt 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 SystemThe 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
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
Aluminum Alloy

• SICOTM Procedure

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
Weld Metal Crack Susceptibility Study

• Conventional LBT Procedure

51
Weld Metal Crack Susceptibility Study

• SICOTM Specimen Cutting

52
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
53
Weld Metal Crack Susceptibility Study

• Using SICOTM Procedure

54
Weld Metal Crack Susceptibility Study

• Micromechanism of Microfissuring

55
Weld Metal Crack Susceptibility Study

• Application of the SICOTM Procedure

Compositions (wt) of the Four Electrodes Tested
56
Weld Metal Crack Susceptibility Study

• Nil-Strength Temperature Measurement

Nil-Strength Temperatures (oC) of Four Electrodes
57
Weld Metal Crack Susceptibility Study

• Application of the SICOTM Procedure

58
Weld Metal Crack Susceptibility Study

• Application of the SICOTM Procedure

59
Weldability Test Technique

• HAZ Hot Ductility Test

60
Weldability Test Technique

• HAZ Hot Ductility Test

61
Fracture Criterion

• Strain Fracture Criterion

62
Fracture Criterion

• Cockcroft and Lathams Plastic Work Fracture
  Criterion

• Modified Plastic Work Fracture Criterion

63
Hot Workability

• Fracture Limit and Reduction of Area

64
Hot Working Process Simulation

• Stopping Response in High Speed Compression (Hit
  2)

65
Hot Working Process Simulation

• Stopping Response in High Speed Compression (Hit
  3)

66
Hot Working Process Simulation

• Hydrawedge System Performance

67
Hot Working Process Simulation

• Hydrawedge System Performance

68
Hot Working Process Simulation

• Three-Hit Test of Hydrawedge Application

69
Hot Working Process Simulation

• Six-Pass Hot Rolling Process Simulation

70
CCT / TTT / Laser Welding

• ISO-QTM Quenching Technique

71
CCT / TTT Studies

• Effect of Deformation on Phase Transformation

72
Laser Measurement

• Patented Laser Tracking System

73
CCT / TTT for Strip Specimen

• Isothermal Plane for CCT

74
Strip Annealing Simulation

• Patented SISR Technique for Deep Drawing Ability
  Test Specimens

75
Strip Annealing Simulation

• Patented SISR Technique for Making Deep Drawing
  Ability Test Specimens

76
Strip Annealing Simulation

• Specimen Heating Using Patented SISR Technique

77
Strip Annealing Process Simulation

• 1mm x 50mm x 200mm Strip Specimen

78
Strip Annealing Process Simulation

• Strip Annealing Jaw System

79
Gleeble Scrip Language

• Pulse Quenching Techniques

80
GLEEBLE Table Programming
81
Visit Gleeble Web Page
W W W.GLEEBLE.COM