Numerical and Experimental Study of Temperature Field for Double Electrode Gas Metal Arc Welding

2014 ◽  
Vol 136 (2) ◽  
Author(s):  
Yu Shi ◽  
Rihong Han ◽  
Jiankang Huang ◽  
Shao Yan
Keyword(s):  
Temperature Field ◽  
Heat Source ◽  
Base Metal ◽  
Heat Input ◽  
Gas Metal Arc Welding ◽  
Source Model ◽  
Welding Parameters ◽  
Heat Source Model ◽  
Double Electrode ◽  
Simulation Results

Based on the features of double electrode gas metal arc welding (DE-GMAW), a new hybrid heat-source model for DE-GMAW was proposed. Using this heat-source model, the temperature fields of DE-GMAW with different welding parameters were simulated. According to the simulation results with different welding parameters, the influence of welding parameters to the heat input to base metal in DE-GMAW were analyzed. To verify the rationality of the hybrid heat-source model of DE-GMAW, the simulation results of the temperature field were compared with the experimental results with same welding parameters. The research results indicate that under the same total current, the heat input to base metal decrease gradually with the increase of by-pass current. In addition, the closer to the welding line from the measured point the greater decrease rate of the heat input to base metal. By the study and comparison of the thermal cycle curve of measured points, the simulation results were in good agreement with the experimental results. These results indicate that the calculated temperature field is accurate and the hybrid heat-source model is rational.

Stress Simulation for DE-GMAW in Bonding Steel with Aluminum

2011 ◽  
Vol 268-270 ◽  
pp. 24-29 ◽  
Author(s):  
Ming Liang Wu ◽  
Jian Kang Huang ◽  
Ri Hong Han ◽  
Yu Shi
Keyword(s):  
Residual Stress ◽  
Base Metal ◽  
Heat Input ◽  
Gas Metal Arc Welding ◽  
Source Model ◽  
Metal Arc Welding ◽  
Double Electrode ◽  
Melting Current ◽  
Metal Welding ◽  
Stress Simulation

DE-GMAW (Double-Electrode Gas Metal Arc Welding) is a new welding technology. It is possible to change the melting current while the base metal current still be controlled at a desired level because the changed part of the melting current would be bypassed without flowing through the workpiece. So the heat input of base metal can be controlled accurately in DE-GMAW, and this welding method is suitable for dissimilar metal welding which has strict requirements for heat input of base metal, such as joining of steel and aluminum. On the basis of heat source model of DE-GMAW, numerical simulation and analysis on temperature field and residual stress for DE-GMAW in bonding steel and aluminum were done. The results show that residual stress after welding changed sharply from close 0 MPa to about 130 MPa at the interface of aluminum and steel. This value is greater than the binding force of steel, aluminum interface.

Effects of Heat Source Model and Welding Speed on Welding Temperature Field for a Plan Carbon Steel Plant

2014 ◽  
Vol 488-489 ◽  
pp. 83-89 ◽  
Author(s):  
Z.K. Song ◽  
Z.Y. Li ◽  
J. Xu ◽  
Y.C. Sun
Keyword(s):  
Temperature Field ◽  
Carbon Steel ◽  
Heat Source ◽  
Welding Speed ◽  
Heat Input ◽  
Source Parameters ◽  
Source Model ◽  
Heat Source Model ◽  
Element Analysis ◽  
Welding Temperature

This article studies the effects of heat source shape parameter and welding speed on the evolution of welding temperature field for Q345 plan carbon steel. The heat input and heat source parameters as well as the welding speed are defined by applying DFLUX subroutine in ABAQUS to simulate the transient welding temperature. The effects of heat resource shape parameters and heat input as well as the welding speed on welding temperature field are investigated by means of finite element analysis. It has been found that heat source parameters and welding speed show strong influence on temperature distribution in FZ (fusion zone) and HAZ (heat-affected zone). Meanwhile, it shows a roughly linear relationship between the changes of heat input and the highest temperature.

scholarly journals Simulating Convective-Radiative Heat Sinks Effect by means of FEA-based Gaussian Heat Sources and Its Approximate Analytical Solutions for Semi-Infinite Body

2021 ◽  
Author(s):  
Ninh The Nguyen ◽  
John H Chujutalli
Keyword(s):  
Temperature Field ◽  
Heat Source ◽  
Analytical Solutions ◽  
Radiative Heat ◽  
Source Model ◽  
Heat Sinks ◽  
Transient Temperature ◽  
Measured Temperature ◽  
Heat Source Model ◽  
Transient Temperature Field

Abstract FEA-based Gaussian density heat source models were developed to study the effect of convective and radiative heat sinks on the transient temperature field predicted by the available approximate analytical solution of the purely conduction-based Goldak’s heat source. A new complex 3D Gaussian heat source model, incorporating all three modes of heat transfer, i.e., conduction, convection and radiation, has been developed as an extension of the Goldak heat source. Its approximate transient analytical solutions for this 3-D moving heat source were derived and numerically benchmarked with the available measured temperature & weld pool geometry data by Matlab programming with ~5 to 6 times faster than FEA-based simulation. The new complex 3D Gaussian heat source model and its approximate solution could significantly reduce the computing time in generating the transient temperature field and become an efficient alternative to extensive FEA-based simulations of heating sequences, where virtual optimisation of a melting heat source (i.e. used in welding, heating, cutting or other advanced manufacturing processes) is desirable for characterisation of material behaviour in microstructure evolution, melted pool, microhardness, residual stress and distortions.

scholarly journals Multi-objective calibration of the double-ellipsoid heat source model for GMAW process simulation

2021 ◽  
pp. 181-181
Author(s):  
Miso Bjelic ◽  
Branko Radicevic ◽  
Karel Kovanda ◽  
Ladislav Kolařík ◽  
Aleksandra Petrovic
Keyword(s):  
Numerical Model ◽  
Heat Source ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Calibration Procedure ◽  
Source Model ◽  
Objective Functions ◽  
Heat Source Model ◽  
Metal Arc Welding ◽  
Input Parameters

The scope of application of simulation models in welding is limited by the accuracy of their output results. This paper presents a calibration procedure for a three-dimensional quasi-stationary model of heat transfer for gas metal arc welding. The double-ellipsoid heat source used in this model has five input parameters whose value cannot be specified accurately. To estimate these values, we employed a multi-objective calibration procedure with two objective functions using the paretosearch optimization algorithm. Objective functions represented the error between simulated and experimentally observed values of penetration depth and weld bead width during gas metal arc welding of P355GH steel plates. All input parameters were assumed to be a power function of line energy. To reduce computational time, we replaced the numerical model with a response surface methodology metamodel based on an optimal set of simulation results from the numerical model. The results of the simulations based on calculated values of input parameters for the heat source model showed excellent matching with the experimental results.

A NEW HEAT SOURCE MODEL FOR KEYHOLE MODE LASER WELDING

2021 ◽  
pp. 1-14
Author(s):  
Samuel Lorin ◽  
Julia Madrid ◽  
Rikard Söderberg ◽  
Kristina Wärmefjord
Keyword(s):  
Heat Source ◽  
Laser Welding ◽  
Heat Input ◽  
Source Model ◽  
Fluid Simulation ◽  
Heat Sources ◽  
Heat Source Model ◽  
Mode Laser ◽  
Standard Heat

Abstract Laser welding is a common technique for joining metals in many manufacturing industries. Due to the heat input and the resulting melting and solidification, the parts deform causing residual distortion and residual stresses. To assure the geometrical and functional quality of the product, Computational Welding Mechanics (CWM) is often employed in the design phase to predict the outcome of different design proposals. Furthermore, CWM can be used to design the welding process with the objective of assuring the quality of the weld. However, welding is a complex multi-physical process and in a design process it is typically not feasible, for example, to employ fluid simulation of the weld pool in order to predict deformation, especially if a set of design proposals is under investigation. Instead, what is used is a heat source that emulates the heat input from the melt pool. However, standard heat sources are typically not flexible enough to capture the fusion zone for deep keyhole mode laser welding. In this paper, a new heat source model for keyhole mode laser welding is presented. In an industrial case study, a number of bead on plate welds have been employed to compare standard weld heat sources and develop the new heat source model. The proposed heat source is based on a combination of standard heat sources. From the study, it was concluded that the standard heat sources could not predict the observed melted zone for certain industrial application while the new heat source was able to do so.

scholarly journals Research on Heat Source Model and Weld Profile for Fiber Laser Welding of A304 Stainless Steel Thin Sheet

2018 ◽  
Vol 2018 ◽  
pp. 1-12 ◽  
Author(s):  
Peizhi Li ◽  
Yu Fan ◽  
Chonghao Zhang ◽  
Zhiyuan Zhu ◽  
Wenteng Tian ◽  
...  
Keyword(s):  
Heat Source ◽  
Laser Welding ◽  
Fiber Laser ◽  
Source Model ◽  
Depth Of Penetration ◽  
Fiber Laser Welding ◽  
Heat Source Model ◽  
Bead Width ◽  
Weld Profile ◽  
Simulation Results

A heat source model is the key issue for laser welding simulation. The Gaussian heat source model is not suitable to match the actual laser weld profile accurately. Furthermore, fiber lasers are widely recognized to result in good-quality laser beam output, a narrower weld zone, less distortion, and high process efficiency, compared with other types of lasers (such as CO2, Nd : YAG, and diode lasers). At present, there are few heat source models for fiber laser welding. Most of researchers evaluate the weld profile only by the bead width and depth of penetration, which is not suitable for the laser keyhole welding nail-like profile. This paper reports an experimental study and FEA simulation of fiber laser butt welding on 1 mm thick A304 stainless steel. A new heat source model (cylindrical and cylindrical) is established to match the actual weld profile using Marc and Fortran software. Four bead geometry parameters (penetration depth, bead width, waist width, and depth of the waist) are used to compare between the experimental and simulation results. The results show that the heat source model of cylindrical and cylindrical can match the actual shape of the fiber laser welding feasibly. The error range of the penetration depth, bead width, waist width, and depth of the waist between experimental and simulation results is about 4.1 ± 1.6%, 2.9 ± 2.0%, 13.6 ± 7.4/%, and 18.3 ± 8.0%, respectively. In addition, it is found that the depth of penetration is more sensitive to laser power rather than bead width, waist width, and depth of the waist. Welding speed has a similar influence on the depth of penetration, weld width, waist width, and depth of the waist.

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