Experimental validation of a predictive model for numerical simulation of thermo-metallurgical phenomena during electron beam welding

2004 ◽  
Vol 120 ◽  
pp. 599-606
Author(s):  
M. Carin ◽  
Ph. Rogeon ◽  
D. Carron ◽  
Ph. Lemasson ◽  
D. Couedel ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Electron Beam ◽  
Heat Affected Zone ◽  
Experimental Validation ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Experimental Measurements ◽  
Finite Element Code ◽  
Thermal Cycles

In the present work, thermal cycles measured with thermocouples embedded in specimens are employed to validate a numerical thermometallurgical model of an Electron Beam welding process. The implemented instrumentation techniques aim at reducing the perturbations induced by the sensors in place. A comparison between simulations performed on finite element code SYSWELD and the experimental measurements carried out on 16MnNiMo5 steel in the case of a partial penetration is achieved. This comparison is based on thermal cycles and also on microstructural evolutions, shapes of fusion zone (FZ) and heat affected zone (HAZ).

Measurement and Simulation of Residual Stresses of Electron Beam Welding Joint of Pure Aluminum

2012 ◽  
Vol 184-185 ◽  
pp. 649-652
Author(s):  
Gui Fang Guo ◽  
Shi Qiong Zhou ◽  
Liang Wang ◽  
Li Hao ◽  
Ze Guo Liu
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Electron Beam ◽  
Residual Stresses ◽  
Electron Beam Welding ◽  
Pure Aluminum ◽  
Research Result ◽  
Welding Process ◽  
Hole Drilling ◽  
Longitudinal Residual Stress

The effects of electron beam welding on the residual stresses of welded joints of pure aluminum plate 99.60 are studied by through-hole-drilling and blind-hole-drilling method. Meanwhile, based on the thermal elastic-plastic theory, and making use of ANSYS finite element procedure, a three - dimensional finite element model using mobile heat source of temperature and stresses field of electron beam welding in pure aluminum is established. The welding process is simulated by means of the ANSYS software. The results show that the main residual stress is the longitudinal residual stress, the value of the longitudinal residual stress is much larger than the transverse residual stress. But the residual stress in the thickness is rather small. And in the weld center, the maximum value of residual stresses is lower than its yield strength. The simulation results about the welded residual stresses are almost identical with the experimental results by measuring. So the research result is important to science research and engineering application.

Numerical Simulation on Temperature Field of Electron Beam Welding of Magnesium Alloy and Study on Properties and Microstructure of Joint

2008 ◽  
Vol 575-578 ◽  
pp. 660-665 ◽  
Author(s):  
Hong Ye ◽  
Yi Luo ◽  
Zhong Lin Yan ◽  
Bin Shen
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Electron Beam ◽  
Magnesium Alloy ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Element Model ◽  
Experimental Result ◽  
Electron Beam Current ◽  
Az61 Magnesium Alloy

Magnesium alloys are being increasingly used in automotive and aerospace structures. In this study, welding of AZ61 magnesium alloy with 10 mm thickness was carried out using vacuum electron beam welding (EBW). By using the finite element model and the 3D moving double ellipsoid heat source model, numerical simulation method was employed to study the influence of the electron beam current on the temperature field of welding process and weld penetration. The microstructure and microhardness of weld joint obtained by the optimized vacuum EBW process had been investigated in detail. The results show that the numerical simulation result basically matches the experimental result. A favorable joint had been obtained by EBW for AZ61 magnesium alloy, in which heat affected zone was not evident, the fusion zone (FZ) consisted of fine-equiaxed grain. The weld hardness was greater than that of the base metal.

Numerical Simulation of Electron Beam Welding Process of Inconel 706 Sheets

2011 ◽  
Vol 473 ◽  
pp. 540-547 ◽  
Author(s):  
Piotr Lacki ◽  
Konrad Adamus ◽  
Kwiryn Wojsyk ◽  
Marcin Zawadzki
Keyword(s):  
Numerical Simulation ◽  
Electron Beam ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Partial Least Square ◽  
Least Square ◽  
Calibration Data ◽  
Element Analysis ◽  
Welding Operation ◽  
Input Parameters

Welding operation of aircraft engine sheet part will be analyzed in this paper. The sheet part is made of narrow Inconel 706 sheet pieces. During manufacturing process first sheets undergo the process of bending. Subsequently they are welded to produce the final shape. Finite element analysis will be used to model welding operation. The thermal field and its impact on the stress field will be analyzed. The produced results will be used to design the actual welding process. Sheets will be welded using electron beam welding, EBW, method. This method is characterized by high concentration of power which instantly melts metal. As a result small HAZ is produced and comparatively small distortions are introduced. EBW process is characterized mainly by three input parameters: beam voltage, beam current and welding speed. The goal of numerical simulation is to identify the values of input parameters that produce full-depth fusion zone. As a guideline for simulation the actual dependency between input parameters and weld pool geometry will be taken from calibration data for EB welding unit. Calibration was performed using 18-8 steel. Partial least square method will be used to project those data on Inconel 706 alloy.

GRADIENT BOOSTING METHOD APPLICATION TO SUPPORT PROCESS DECISIONS IN THE ELECTRON-BEAM WELDING PROCESS

2020 ◽  
Vol 21 (2) ◽  
pp. 206-214
Author(s):  
V. S. Tynchenko ◽  
◽  
I. A. Golovenok ◽  
V. E. Petrenko ◽  
A. V. Milov ◽  
...  
Keyword(s):  
Electron Beam ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Gradient Boosting ◽  
Boosting Method

Numerical Simulation of the Effects of Preheating on Electron Beam Additive Manufactured Ti-6Al-4V Build Plate

2016 ◽  
Vol 879 ◽  
pp. 274-278 ◽  
Author(s):  
Jun Cao ◽  
Philip Nash
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Finite Element ◽  
Electron Beam ◽  
Cross Section ◽  
Element Model ◽  
Normal Direction ◽  
Thermal Residual Stresses ◽  
Longitudinal Residual Stress ◽  
Middle Cross Section

In an earlier study, a 3-D thermomechanical coupled finite element model was built and experimentally validated to investigate the evolution of the thermal residual stresses and distortions in electron beam additive manufactured Ti-6Al-4V build plates. In this study, an investigation using this robust and accurate model was focused on an efficient preheating method, in which the electron beam quickly scanned across the substrate to preheat the build plate prior to the deposition. Various preheat times, beam powers, scan rates, scanning paths and cooling times (between the end of current preheat scan/deposition layer and the beginning of the next preheat scan/deposition layer) were examined, and the maximum distortion along the centerline of the substrate and the maximum longitudinal residual stress along the normal direction on the middle cross-section of the build plate were quantitatively compared. The results show that increasing preheat times and beam powers could effectively reduce both distortion and residual stress for multiple layers/passes components.

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