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www.springerlink.com/content/1738-494x(Print)/1976-3824(Online)
DOI 10.1007/s12206-016-0750-0
Smart Microsystem Research Laboratory, Department of Advanced Technology Fusion, Division of Interdisciplinary Studies, Konkuk University,
120 Neungdong-ro, Gwangjin-gu, Seoul 143-701, Korea
2
Agency for Defense Development, The 1st R&D institute-2, Yuseong P.O. Box 35, Daejeon 305-600, Korea
(Manuscript Received November 3, 2015; Revised March 31, 2016; Accepted April 12, 2016)
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Abstract
During the high speed flight of vehicles, the thermal behavior and interactions of structures in a high-temperature environment are important for thermal-structural design. In this research, the thermal interaction behavior of a circular aluminum plate inside a stainless steel
ring was investigated at temperature up to 550C using a non-contact and full-field high-temperature deformation measurement method.
This study uses an infrared radiation heating system to create a high-temperature operation environment. The techniques were developed
and implemented in a radiation heating facility, enabling non-contact displacement, strain measurements through Digital image correlation (DIC) technique. The images of the structure surface due to thermal load at various temperatures were recorded with Chargedcoupled device cameras. Afterwards, full-field thermal deformation of the sample was determined with DIC technique. Finally, finite
element analysis was used to calculate high-temperature deformation of the circular plate-ring structure. The results of the experiment
were close to the simulation results. In addition, the process of both heating-up and cooling-down was also considered to examine the
recoverable characteristic of the structure. The results show the efficacy of DIC in achieving such measurements at high-temperatures.
Keywords: Thermal deformation; Digital image correlation (DIC); Finite element method (FEM); Thermal stresses; Thermal interaction
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1. Introduction
High-speed vehicles have to withstand very high aerodynamic heating and pressure loads during ascent and flight
processes. In hypersonic speeds, aero-thermal heating raises
temperatures, which in turn affects elastic properties such as
decreasing Youngs modulus, ultimately reducing the capability of the material to handle aerodynamic loads, the allowable
stress and the time-dependent phenomenon. Thermal stresses
then become important factors due to thermal expansion or
thermal contraction, and they induce many problems such as
dimension changes in the buckling loads and the flutter behavior [1]. Therefore, the thermal stress caused by hightemperature interactions of hot structures should be investigated to address these problems.
The high-temperature behaviors of a structure have been
investigated experimentally by many researchers. Anwander
et al. [2] presented a non-contacting strain measurement at a
temperature of 1200C with the digital laser speckle technique. A measurement of the thermal strain of pure platinum
*
Corresponding author. Tel.: +82 2 450 4133, Fax.: +82 2 444 7091
E-mail address: nsgoo@konkuk.ac.kr
at ultra-temperatures was also carried out using a video extensometer [3]. A thermo-mechanical model of bearing was
proposed to see the effect of bearing temperature on the stiffness [4]. There have been a number of non-contact optical
measurement methods proposed to characterize materials at
high temperatures such as the laser speckle correlation [5], Xray diffraction [6], electronic speckle pattern interferometry
[7], and the digital image correlation (DIC) technique [8-20]
or infrared image correlation [14]. Compared to the other
methods, the DIC technique offers many advantages such as
a simple experimental set-up, full-field measurement, a large
strain measurement [20, 21], a high strain-gradient region
[19], and rigid body motion elimination [22], insensitivity to
vibrations, arbitrary specimen size [23] and easy preparation
of specimens.
Due to the many advantages, researchers have used DIC
techniques to measure thermal deformation. Lyons et al. assessed the capability of the two-dimensional (2-D) computervision method based on DIC technique to measure full-field
and in-plane surface deformations of Incoloy 909 and Inconel
718 super alloy at evaluated temperatures up to 650C [9].
The 2-D DIC method was then applied to determine the Coefficient of thermal expansion (CTE) of thin metallic films
[10, 15, 24]. Chen et al. [8] measured the displacement and
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Table 1. Elastic moduli and CTEs of aluminum and stainless steel were
taken from ASM and MMPDS handbook.
Aluminum (AL-2024-T351)
Temp.
(C)
CTEa
(10-6
m/m/C)
Elastic
modulusb
(GPa)
CTEc
(10-6
m/m/C)
Elastic
modulusb
(GPa)
Fig. 4. In situ experimental setup, heating from the front side of the
specimen (facing the heater) is shown on the right side. The image on
the left side shows the arrangement of experiment.
gap between the outer ring and the inner plate decreased. Contact temperature is defined as the temperature at which the gap
disappears shown in following equation [11]
50
21.3
76.69
16
198
100
21.6
75.24
16
195
150
21.1
72.35
16.3
191
200
21.6
67.29
16.5
187
250
22.3
64.24
16.8
184
300
23.4
61.19
17.5
182
350
24.2
58.9
17.8
177
400
25.07
57.0
18.0
172
450
25.68
52.5
18.1
166
500
26.44
50.0
18.2
161
550
26.95
48.0
18.4
158
a, b
Tcontact
GAP
,
= TR +
RAL a AL - RSteel a steel
(1)
Fig. 5. Modeling of the structure in ABAQUS, the gap is 0.2 mm, and
the half-model of the structure was used to reduce the time required for
the analyses.
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(a)
(a)
(b)
Fig. 7. uy displacement from 520C to 540C, respectively: (a) ydisplacements from 520C to 530C; (b) y-displacement from 530C to
540C (unit: m).
(b)
Fig. 6. Comparisons of the uy displacement fields of the double ring at
(a) 200C; (b) 550C (unit: mm).
Fig. 8. Diameter changes of inner plate and outer ring from analysis
and measurement.
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(a)
(b)
Fig. 11. Total strain field of the structure calculated at 200C from the
analysis and the ARAMIS software. The contour was from 0 to 3%.
(a)
(b)
Fig. 12. Total strain field of the structure calculated at 550C from the
analysis and the ARAMIS software. The contour was from 0 to 3%.
thermal
(2)
0
aDT
=
0
a
D
T
e xxtotal - aDT
M =
e yx
e xy
e yytotal - aDT
(3)
(4)
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(a)
Fig. 14. Change in length of the inner aluminum plate during the heating and cooling processes, Dd (mm).
(b)
Fig. 13. Stress fields calculated by FEM and measured by ARAMIS
software for the circular plate-ring structure at 550C. The contour was
from -25 to 60 MPa.
2
s xx 1 - v
vE
s yy =
2
s 1 - v
xy 0
vE
1 - v2
E
1 - v2
0
0
e xxM
0 e yyM
M
2e
G xy
(5)
where M, total, thermal are the mechanical strain, the total strain,
and the thermal strain, respectively. The elastic modulus,
Poissons ratio, and shear modulus are denoted by E, and G,
respectively.
Fig. 13 shows the comparisons of the stress fields measured
by the ARAMIS software and that calculated from the finite
element analysis at 550C. The aluminum plate was in compression, and the xx and yy were -13.1 MPa and -10.6 MPa at
the center of the plate, respectively. Compared with that from
analysis, those values were -13.6 MPa and -13.6 MPa, respectively. The comparison of the stress between the measurement
results and the simulation results show that the values for largest difference were 35% and 11% in xx and yy, respectively.
The results show that there is a significant difference in stress
between the measurement and simulation due to measurement
errors and the non-uniform distribution of the temperature
across the whole aluminum circular plate. The stress field
contours of the measurement result show a non-uniform dis-
tribution (non-symmetric) of contact stress at the top and bottom of the aluminum circular plate due to the initial contact
area of the two structures. There is pre-contact stress occurring
at the bottom area before the two structures come into contact
at the top. A flaw in the configuration of the set-up was assumed when putting the inner aluminum circular plate inside
the outer stainless steel ring, even though we did our best to
ensure perfect experimental conditions.
According to material properties data [35], the yield
strength of aluminum alloy-2024 is about 345 MPa at a temperature of 25C and 27.2 MPa at 550C. As shown in Fig. 13,
the maximum stress of the structure is about 25 MPa, which is
still smaller than the yield strength of the material at 550C.
Consequently, we can say that the structure did not reach the
plasticity region.
3.3 Thermal contraction of the structure
After contacting the stainless steel, the aluminum plate continued to expand. The temperature reached 550C, and then,
the heater was switched off and structure was cooled to 50C
in natural room cooling conditions at a rate of approximately
15C/min shown in Fig. 14. To investigate the recoverable
capability of the materials, the diameter change of inner aluminum plate was performed with time (sec). The biggest
change of diameter of the inner circular plate and the inner
diameter of the outer ring were 0.693 mm and 0.495 mm at
550C, respectively.
After doing image correlation processing in the ARAMIS
software with 14 deformed images, we obtained the displacement field during the cooling process of the structure. Figs.
15(a) and (b) show a comparison of the diameter changes
during the heating and cooling process at various temperatures.
The comparisons show the recovery capability of the inner
aluminum plate and the inner diameter of the outer ring, respectively. According to the results, this material tends to recover to its initial size at 50C. This result means that the material can recover to its original shape and dimension because
it deforms within the elastic region. The significant differences
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Acknowledgment
This work was conducted at High-Speed Vehicle Research
Center of KAIST with the support of Defense Acquisition
Program Administration (DAPA) and Agency for Defense
Development (ADD). The authors are grateful for the financial support.
Nomenclature------------------------------------------------------------------------
(b)
Fig. 15. Recovery capability of the structure during the heating and
cooling processes: (a) Change in the diameter of the inner aluminum
plate; (b) change in the inner diameter of the outer stainless steel ring.
4. Conclusions
The present study used the digital image correlation technique to study and characterize the thermal interaction and
behavior of the circular plate-ring structure at temperatures up
to 550C. The structure was heated at heating rate of
60C/min by a radiation heater. The contact temperature of the
structure was predicted by theoretical calculation. It was also
determined by experimental results. To validate the experimental results, an analysis was performed using ABAQUS.
TR
RAL
RST
GAP
AL
ST
M
total
thermal
E
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