Modelling and process optimization for functionally graded materials

Ravi S. Bellur-Ramaswamy, Robert Haber, Nahil A. Sobh, Daniel A. Tortorelli

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

We optimize continuous quench process parameters to produce functionally graded aluminum alloy extrudates. To perform this task, an optimization problem is defined and solved using a standard nonlinear programming algorithm. Ingredients of this algorithm include 1) the process parameters to be optimized, 2) a cost function: the weighted average of the precipitate number density distribution, 3) constraint functions to limit the temperature gradient (and hence distortion and residual stress) and exit temperature, and 4) their sensitivities with respect to the process parameters. The cost and constraint functions are dependent on the temperature and precipitate size which are obtained by balancing energy to determine the temperature distribution and by using a reaction-rate theory to determine the precipitate particle sizes and their distributions. Both the temperature and the precipitate models are solved via the discontinuous Galerkin finite element method. The energy balance incorporates nonlinear boundary conditions and material properties. The temperature field is then used in the reaction rate model which has as many as 105 degrees-of-freedom per finite element node. After computing the temperature and precipitate size distributions we must compute their sensitivities. This seemingly intractable computational task is resolved thanks to the discontinuous Galerkin finite element formulation and the direct differentiation sensitivity method. A three-dimension example is provided to demonstrate the algorithm.

Original languageEnglish (US)
Title of host publicationProceedings of the Conference on Computational Modeling of Materials, Minerals and Metals Processing
EditorsM. Cross, J.W. Evans, C. Bailey, M. Cross, J.W. Evans, C. Bailey
Pages65-84
Number of pages20
StatePublished - 2001
EventProceedings of Conference on Computational Modeling of Materials, Minerals and Metals Processing - San Diego, CA, United States
Duration: Sep 23 2001Sep 26 2001

Publication series

NameProceedings of the Conference on Computational Modeling of Materials, Minerals and Metals Processing

Other

OtherProceedings of Conference on Computational Modeling of Materials, Minerals and Metals Processing
Country/TerritoryUnited States
CitySan Diego, CA
Period9/23/019/26/01

ASJC Scopus subject areas

  • General Engineering

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