Validation of Materials-Informed Digital Twin: Mapping Residual Strains in HSLA Steel Weldment Using High Energy X-Rays
Abstract
The U.S. Navy has placed an emphasis on establishing digital twin prototypes across all of its assets. However, material processing data is not currently included in simulations for structural performance, which could lead to inaccuracies in lifecycle analysis. Integrated Computational Materials Engineering (ICME) techniques yield a path to solving this problem through linking digital information across multiple length scales in order to minimize the time and cost of physical testing needed for validation. This report is part of a planned four-part series detailing the entire materials-informed digital twin effort. This report details the selection and fabrication of the sister sample specimens, finite-element analysis (FEA)-based welding simulations of the final reinforced dog-bone weldment, and comparison of predicted strain data to two-dimensional (2D) strain maps produced at the Cornell High-Energy Synchrotron Source (CHESS). The second report will detail additional FEA analysis of rolled plate in comparison to through-thickness strain measurement at CHESS. The third report will detail efforts to further validate the CHESS measurements at neutron diffraction facilities. Lastly, the fourth report will include FEA simulations of mechanical performance (with incorporated material processing data) in comparison to physical testing of the final weldment. As part of the current effort, a set sister-samples to represent various steps in the fabrication process was produced from a single plate of 25.4 mm (1-in.) thick HSLA-100 steel. Specimen #1 represented incoming rolled plate, Specimen #2 represented cut pieces, and Specimen #3 represented the final reinforced dog-bone welded structure. Initial FEA analysis of the final weldment showed high tensile stresses near the weld passes in the heat-affected zone (HAZ), as expected. Validation of the predicted strain within the dog-bone shape was completed using EDD measurements at CHESS.
Document Details
- Document Type
- Technical Report
- Publication Date
- Aug 13, 2020
- Accession Number
- AD1124147
Entities
People
- Armand J. Beaudoin
- Charles R. Fisher
- Kelly E. Nygren
Organizations
- Cornell High Energy Synchrotron Source
- Naval Surface Warfare Center