Friction stir welding (FSW) has been studied extensively for the past two decades. Thermal modeling has been of particular interest, as the quality of the weld is dependent upon the temperature history of the work piece during the process. Since direct temperature measurements of the welded zone are not possible, an analytical model was developed to predict the temperature in this area. This model requires parameters that cannot be easily experimentally determined, so a best fit for these parameters was acquired via regression analysis by comparing the model to experimental data acquired outside of the weld zone. The model was then validated by comparing it to additional temperature data, not including the data used for regression analysis.

No description available.

We have created a three-dimensional, implicit finite difference model that can accurately calculate temperatures within the bulk of a sample during a friction stir fabrication process. The model was written in Wolfram Mathematica® 7 for Students, and allows for time-efficient calculation of thermal profiles. The non-dimensionality of the model allows for accurate refinement of the temporospatial mesh, and provides portability across material types. The model provides insight as to the mechanism of heat generation by qualifying the fraction of mechanical energy converted to thermal energy for different material types and sample geometries. Finally, our model gives an understanding of the effects of the heat transfer at the boundaries of the workpiece and suggests a backside heat loss localized at the center of the tool due to a decrease in thermal contact resistance. We have explored the effects of processing parameters on the performance of the friction stir fabrication process. The process has four stages; tool insertion, warm-up, bead formation, and steady-state translation. The tool insertion phase is characterized by a rapid increase in system horsepower requirements. During the warm-up phase, the mechanical energy of the rotating tip is converted to thermal energy. Once enough thermal energy has been transferred to the workpiece, the volume between the tip and the workpiece is filled by feedstock material. Finally, the tool is translated under relatively steady-state conditions. The success or failure of the process is dependent on adequate material delivery to the system. The horsepower requirements of the process depend on the material type and the rate of material delivery. We have explored the effect of processing parameters on the microstructure of the processed samples. Optical microscopy shows that the stratification of layers within the weld and the depth of the weld are both dependent on the processing parameters. EBSD analysis coupled with Vicker's microhardness measurements of the processed pieces show that the grain size within the weld nugget is constant over the range of processing parameters available to the system. Data also show that pressure and heat inherent in friction stir processing of strain-hardened Al5083 counteract strengthening of the temper of the alloy. / Ph. D.

Electric motors for vehicle applications are required to have high efficiency and small size and weight. Accurately modeling the thermal properties of an electric motor is critical to properly sizing the motor. Improving the cooling of the motor windings allows for a more efficient and power-dense motor. There are a variety of methods for predicting motor temperatures, however this paper discusses the advantages and accuracy of using a nodal lumped thermal model. Both commercially available and proprietary motor thermal modeling software are evaluated and compared. Thermal improvements based on the model in both contact interfaces and winding encapsulant are evaluated, showing motor improvements in the ability to handle heat losses of approximately forty percent greater than the baseline, resulting in either higher power or lower motor temperatures for the same package size. / Master of Science

Improving the climate system of cars is important since it is the largest auxiliary load in a standard vehicle with an increase of fuel consumption by up to 20%. In Electric Vehicles (EV) the range of the car is more limited than in a fossil fueled car; furthermore there is a limited waste heat available from the EV, approximately 2-3kW at 40oC for heating and defogging in winter. The goals of this report have been part of an existing European project (ICE) where the climate system of an electric minibus is being investigated. The specific objectives of this project were to develop a radiation model and integrate it in the existing thermal model of the cabin, validating the new model with existing experimental data, including the thermal model in the overall model of the complete vehicle and to use the existing AC-model to optimize the control with the aim of decreasing the energy consumption maintaining thermal comfort inside the cabin. The radiation model uses total radiation on a horizontal surface in order to calculate the radiation hitting the different parts of the car body and windows, finally the total radiative power entering the minibus is calculated. After including these calculations into the thermal model it could be seen that the results from the model in terms of cabin temperatures fit the experimental values surprisingly well. The control of the AC-system was optimized for a hot and sunny summer day in Italy which resulted in the AC-system working very hard following that the best control strategy was to reduce only the speed of the compressor in order to save energy. Calculations show that in the Normal European Driving Cycle (NEDC) the potential energy savings of following this control strategy can result in an energy saving of the AC-system by up to 27% compared to an unregulated case, with a maintained thermal comfort resulting in 4,2% increase in autonomy.

No description available.

The thermal regime of a gearbox is of considerable importance to its performance. Several significant gearbox parameters, such as the efficiency and fatigue life of its components, are temperature dependent. It is thus important to be able to determine the temperatures of the gearbox components during operation, but they are difficult to measure experimentally. A simulation model capable of predicting these temperatures would therefore be a valuable tool. The objective of this master’s thesis was to create a model capable of simulating the thermal regime of a truck gearbox during operation. To do this, mechanical losses in the gearbox, heat exchange with the surroundings, as well as heat transfer between components had to be accounted for. The model was created using the 1D simulation software LMS Imagine.Lab Amesim 14.0, and is based on a combination of mechanical and thermal networks. Details of the mechanical and thermal interactions between components are calculated using empirical and analytical formulas for mechanical losses and heat transfer. The result of the thesis is a model which can be used to simulate either real or idealised load cases, from which temperatures of gear wheels, shafts, bearings, housing and gearbox oil may be studied, as well as gearbox losses and heat transfer. Comparisons between simulated and measured gearbox efficiencies show good correlation. It is also shown that the model can predict oil temperatures which agree with in-vehicle measurements. Due to a lack of measurement data, most simulated component temperatures cannot be compared to measured values. However, temperature measurements performed for one of the gear wheels indicate that the model can be used to predict their temperature. In order to demonstrate the capabilities of the model, example results from both real and idealised load cases are presented.

Fuel cells are predicted to be the power delivery devices of the future. They have many advantages such as the wide fuel selection, high energy density, high efficiency and an inherent safety which explains the immense interest in this power source. The need for advanced designs has been limited by the lack of understanding of the transport processes inside the fuel cell stack. The reactant gases undergo many processes in a fuel cell that cannot be observed. Some of these processes include convective and diffusional mass transport through various types of materials, phase change and chemical reaction. In order to optimize these variables, an accurate mathematical model can provide a valuable tool to gain insight into the processes that are occurring. The goal of this dissertation is to develop a mathematical model for polymer electrolyte-based fuel cells to help contribute to a better understanding of fuel cell mass, heat and charge transport phenomena, to ultimately design more efficient fuel cells. The model is a two-phase, transient mathematical model created with MATLAB. The model was created by using each fuel cell layer as a control volume. In addition, each fuel cell layer was further divided into the number of nodes that the user inputs into the model. Transient heat and mass transfer equations were created for each node. The catalyst layers were modeled using porous electrode equations and the Butler-Volmer equation. The membrane model used Fick's law of diffusion and a set of empirical relations for water uptake and conductivity. Additional work performed for this dissertation includes a mathematical model for predicting bolt torque, and the design and fabrication of four fuel cell stacks ranging in size from macro to micro scale for model validation. The work performed in this dissertation will help improve the designs of polymer electrolyte fuel cells, and other polymer membrane-based fuel cells (such as direct methanol fuel cells) in the future.

The conventional method of thermal modeling of space payloads is expensive and cumbersome. Radiation plays an important part in the thermal modeling of space payloads because of the presence of vacuum and deep space viewing. This induces strong nonlinearities into the thermal modeling process. There is a need for extensive correlation between the model and test data. This thesis presents Online Parameter Estimation as an approach to automate the thermal modeling process. The extended Kalman fillter (EKF) is the most widely used parameter estimation algorithm for nonlinear models. The unscented Kalman filter (UKF) is a new and more accurate technique for parameter estimation. These parameter estimation techniques have been evaluated with respect to data from ground tests conducted on an experimental space payload.

The surface heat flow (qs) is paramount for modeling the thermal structure of the lithosphere. Changes in the qs over a distinct lithospheric unit are normally directly reflecting changes in the crustal composition and therewith the radiogenic heat budget (e.g., Rudnick et al., 1998; Förster and Förster, 2000; Mareschal and Jaupart, 2004; Perry et al., 2006; Hasterok and Chapman, 2011, and references therein) or, less usual, changes in the mantle heat flow (e.g., Pollack and Chapman, 1977). Knowledge of this physical property is therefore of great interest for both academic research and the energy industry. The present study focuses on the qs of central and southern Israel as part of the Sinai Microplate (SM). Having formed during Oligocene to Miocene rifting and break-up of the African and Arabian plates, the SM is characterized by a young and complex tectonic history. Resulting from the time thermal diffusion needs to pass through the lithosphere, on the order of several tens-of-millions of years (e.g., Fowler, 1990); qs-values of the area reflect conditions of pre-Oligocene times. The thermal structure of the lithosphere beneath the SM in general, and south-central Israel in particular, has remained poorly understood. To address this problem, the two parameters needed for the qs determination were investigated. Temperature measurements were made at ten pre-existing oil and water exploration wells, and the thermal conductivity of 240 drill core and outcrop samples was measured in the lab. The thermal conductivity is the sensitive parameter in this determination. Lab measurements were performed on both, dry and water-saturated samples, which is labor- and time-consuming. Another possibility is the measurement of thermal conductivity in dry state and the conversion to a saturated value by using mean model approaches. The availability of a voluminous and diverse dataset of thermal conductivity values in this study allowed (1) in connection with the temperature gradient to calculate new reliable qs values and to use them to model the thermal pattern of the crust in south-central Israel, prior to young tectonic events, and (2) in connection with comparable datasets, controlling the quality of different mean model approaches for indirect determination of bulk thermal conductivity (BTC) of rocks. The reliability of numerically derived BTC values appears to vary between different mean models, and is also strongly dependent upon sample lithology. Yet, correction algorithms may significantly reduce the mismatch between measured and calculated conductivity values based on the different mean models. Furthermore, the dataset allowed the derivation of lithotype-specific conversion equations to calculate the water-saturated BTC directly from data of dry-measured BTC and porosity (e.g., well log derived porosity) with no use of any mean model and thus provide a suitable tool for fast analysis of large datasets. The results of the study indicate that the qs in the study area is significantly higher than previously assumed. The new presented qs values range between 50 and 62 mW m⁻². A weak trend of decreasing heat flow can be identified from the east to the west (55-50 mW m⁻²), and an increase from the Dead Sea Basin to the south (55-62 mW m⁻²). The observed range can be explained by variation in the composition (heat production) of the upper crust, accompanied by more systematic spatial changes in its thickness. The new qs data then can be used, in conjunction with petrophysical data and information on the structure and composition of the lithosphere, to adjust a model of the pre-Oligocene thermal state of the crust in south-central Israel. The 2-D steady-state temperature model was calculated along an E-W traverse based on the DESIRE seismic profile (Mechie et al., 2009). The model comprises the entire lithosphere down to the lithosphere–asthenosphere boundary (LAB) involving the most recent knowledge of the lithosphere in pre-Oligocene time, i.e., prior to the onset of rifting and plume-related lithospheric thermal perturbations. The adjustment of modeled and measured qs allows conclusions about the pre-Oligocene LAB-depth. After the best fitting the most likely depth is 150 km which is consistent with estimations made in comparable regions of the Arabian Shield. It therefore comprises the first ever modelled pre-Oligocene LAB depth, and provides important clues on the thermal state of lithosphere before rifting. This, in turn, is vital for a better understanding of the (thermo)-dynamic processes associated with lithosphere extension and continental break-up. / Der Oberflächenwärmefluss (qs) ist maßgeblich für die Modellierung der thermischen Struktur der Lithosphäre. Änderungen im qs, innerhalb eines speziellen lithosphärischen Abschnitts, reflektieren direkt Änderungen in der krustalen Zusammensetzung und damit der radiogenen Wärmeproduktion (e.g., Rudnick et al., 1998; Förster und Förster, 2000; Mareschal und Jaupart, 2004; Perry et al., 2006; Hasterok und Chapman, 2011) oder aber, weniger häufig, Änderungen im Mantelwärmefluss (e.g., Pollack und Chapman, 1977). Die Kenntnis dieses physikalischen Parameters ist daher von großem Interesse, sowohl für die Forschung als auch für die Energiewirtschaft. Die vorliegende Studie befasst sich mit dem qs von Süd- und Zentralisrael als Teil der Sinai Mikroplatte (SM), welche während des Riftings und Auseinanderbrechens der Afrikanischen und Arabischen Platte im Oligozän entstand und durch diese, sehr junge und komplexe tektonische Geschichte, geprägt ist. Die thermische Diffusion benötigt einige Zehner-Millionen Jahre (e.g., Fowler, 1990) um die Lithosphäre zu durchlaufen, qs-Werte der Region reflektieren daher prä-oligozäne Bedingungen. Die thermische Struktur der Lithosphäre in Süd- und Zentralisrael, ist bis heute nur sehr wenig verstanden. Um dieses Problem anzugehen wurden die Parameter die für die qs-Bestimmung benötigt werden, eingehend untersucht. An zehn ehemaligen Wasser- und Erdölexplorationsbohrungen wurden neue Temperaturmessungen durchgeführt, und die Wärmeleitfähigkeit von 240 Bohrkern- und Aufschlussproben wurde im Labor gemessen. Die Wärmeleitfähigkeit ist in der qs-Bestimmung der sensitive Parameter. Die Labormessungen wurden sowohl an trockenen sowie an wasser-gesättigten Proben durchgeführt, was personal-und zeitaufwendig ist. Eine andere Möglichkeit ist die Messung der Wärmeleitfähigkeit im trockenen Zustand und das Konvertieren zu einem saturierten Wert unter der Verwendung von Mischungsgesetzen. Das Vorhandensein eines umfangreichen und sehr diversen Wärmeleitfähigkeit-Datensatzes ermöglicht (1) in Verbindung mit dem Temperaturgradienten die Berechnung von neuen zuverlässigen qs-Werten sowie deren Verwendung zur Modellierung der thermischen Struktur der prä-oligozänen Kruste in Israel und (2) in Verbindung mit vergleichbaren Datensätzen, die vorhandenen Mischungsgesetzte zur indirekten Bestimmung der saturierten Gesamtwärmeleitfähigkeit (BTC) qualitativ zu überprüfen. Die Zuverlässigkeit numerisch bestimmter BTC-Werte variiert für die verschiedenen Mischungsgesetze und ist darüber hinaus stark von der Lithologie der Proben abhängig. Mittels spezifischer Korrekturgleichungen können Abweichungen zwischen gemessenen und berechneten Werten jedoch erheblich reduziert werden. Die Datenanzahl und die statistische Analyse ermöglichte darüber hinaus die Ableitung von lithotypspezifischen Konvertierungsgleichungen, um die saturierte BTC anhand von trocken gemessenen BTC- und Porositätswerten (z.B. aus Logs) zu berechnen. Dieser Ansatz führt, für alle Lithotypen, zu einer guten Reproduzierbarkeit gemessener Werte und ist daher eine nützliche Alternative, wann immer große Probenmengen behandelt werden. Die Ergebnisse dieser Studie zeigen, dass der qs im Untersuchungsgebiet signifikant höher ist, als bisher angenommen. Die qs-Werte, die in dieser Studie für Israel bestimmt wurden, schwanken zwischen 50 und 62 mW m⁻². Ein schwacher Trend abnehmender Werte von Ost nach West (55-50 mW m⁻²), und ein leichter Trend ansteigender Werte vom Toten Meer nach Süden (55-62 mW m⁻²) können identifiziert werden. Diese beobachteten Schwankungen lassen sich mit Variationen in der krustalen Zusammensetzung (Wärmeproduktion) erklären, einhergehend mit regionalen Änderungen der Krustenmächtigkeit. Die neuen qs-Daten können dann, im Zusammenhang mit petrophysikalischen Daten und Informationen über die Struktur und Zusammensetzung der Lithosphäre, verwendet werden um ein Model des prä-oligozänen thermischen Zustandes der Kruste Zentral- und Südisraels abzugleichen. Das stationäre 2-D Temperatur-Modell wurde entlang einer E-W Traverse, basierend auf dem seismischen DESIRE-Profil (Mechie et al., 2009), berechnet. Es reicht bis zur Lithosphären–Asthenosphären Grenze (LAB) und bezieht sich auf das aktuellste Wissen über die prä-oligozäne Lithosphäre, also vor dem Einsetzen von Rifting und plumebedingten thermischen Störungen. Durch den Abgleich zwischen gemessenen und modellierten qs-Werten ist es möglich auf die prä-oligozäne LAB-Tiefe zurückzuschließen. Als wahrscheinlichste Tiefe ergeben sich 150 km, was konsistent ist mit LAB-Tiefen Abschätzungen aus vergleichbaren stabilen Regionen des Arabischen Schildes. Dies liefert wichtige Anhaltspunkte über den thermischen Zustand der Lithosphäre vor dem Einsetzen von Rifting in der Region und ist wiederum entscheidend für ein besseres Verständnis der dynamischen Prozesse in Assoziation mit Extension der Lithosphäre und dem kontinentalem Auseinanderbrechen.