ICME-W predictive model for thermal-mechanical response during paint-baking of dissimilar metal

Automotive structures are increasingly utilizing dissimilar metals such as advanced high strength steels and high-strength aluminum alloys to reduce weight. As steels and aluminum alloys have different coefficients of thermal expansion, structures made of these two materials are susceptible to deflection during paint-bake. In a project sponsored by DOE Vehicle Technologies Program, Prof. Wei Zhang's group developed a predictive model for thermal-mechanical response during paint-baking of dissimilar metal structures. Picture below shows that the deflection profile at peak temperature (197 degC) predicted by the model is very consistent with that measured experimentally. The model can be used design the part geometry as well as pitch distance between joints to reduce the thermally-induced deflection.  More information can be found in this report.

Predictive model for thermal-mechanical response during paint-baking Wei Zhang Ohio State welding engineering
Comparison of predicted and measured deflection at paint-bake peak temperature (*Experimental data courtesy of Oak Ridge National Laboratory)

 

pitch distance reduces thermally-induced deflection during paint-bake Wei Zhang Ohio State welding engineering
Decreasing pitch distance significantly reduces thermally-induced deflection during paint-bake.
Category: Integrated Computational Materials Engineering for Welding
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