Numerical Modeling of Thermo-Fluid Flow and Metal Mixing in Laser Keyhole Welding of Dissimilar Metals

Author(s):  
Wenda Tan ◽  
Wenkang Huang

In laser keyhole welding of dissimilar metals, the thermo-fluid flow in the molten pool has decisive effects on the compositional mixing of different chemical elements and hence the formation of detrimental intermetallic compounds. A numerical model is developed in this work to investigate the composition mixing in laser keyhole welding of dissimilar metals. The model takes into account multiple important physics in the process, including dynamic keyhole evolution, laser matter-interaction, phase change, thermo-fluid flow, and composition diffusion/advection. The preliminary simulation results demonstrate that the keyhole behavior is strongly affected by the properties of the dissimilar metals, and the keyhole fluctuation causes an unstable flow in the molten pool that facilitates the compositional mixing through advection.

2015 ◽  
Vol 46 (7) ◽  
pp. 3140-3156 ◽  
Author(s):  
Virginia Garcia Navas ◽  
Josu Leunda ◽  
Jon Lambarri ◽  
Carmen Sanz

2010 ◽  
Vol 97-101 ◽  
pp. 3001-3004 ◽  
Author(s):  
Sheng Yong Pang ◽  
Li Liang Chen ◽  
Ya Jun Yin ◽  
Ai Qin Duan ◽  
Jian Xin Zhou ◽  
...  

Numerical simulation provides a way to improve our understandings of the heat transfer and fluid flow behaviors of the weld pool during laser keyhole welding. However, current numerical studies are only limited to serial simulations which running on a single CPU. In this study, a parallel numerical study of the heat transfer and fluid flow of the weld pool is presented. A mathematical model considering the effect of Marangoni force, buoyancy force, friction force of the mushy zone region and the effect of keyhole is presented. A combined keyhole volume and surface heat source model is also developed. The coupled transient heat transfer and Navier-stokes equations are solved with a high order accuracy parallel projection method. The simulation code is parallelized with the OpenMP language. It is shown that 200% speedup can be achieved on a shared memory quad-core CPU using the presented parallel simulation system. The simulation results agree well with the in-situ high speed CCD video imaging experiments and the literature results.


2020 ◽  
Vol 195 ◽  
pp. 109056 ◽  
Author(s):  
Wenkang Huang ◽  
Hongliang Wang ◽  
Teresa Rinker ◽  
Wenda Tan

2021 ◽  
Vol 114 (1-2) ◽  
pp. 117-130
Author(s):  
Wai Jun Lai ◽  
Supriyo Ganguly ◽  
Wojciech Suder

AbstractLaser keyhole initiation and termination-related defects, such as cracking and keyhole cavities due to keyhole collapse, are a well-known issue in laser keyhole welding of thick section steels. In longitudinal welding, run-on and run-off plates are used to avoid this problem. However, such an approach is not applicable in circumferential welding where start/stop defects remain within the workpiece. These issues can hinder industry from applying laser keyhole welding for circumferential welding applications. In this paper, the effect of inter-pass temperature on laser keyhole initiation and termination at the weld overlap start-stop region was investigated. This study has identified that defects occurring within this region were due to laser termination rather than laser initiation because of keyhole instabilities regardless of the thermal cycle. The laser termination defects were mitigated by applying a laser defocusing termination regime to reduce the keyhole depth gradually and control the closure of the keyhole.


Author(s):  
M. Jamshidinia ◽  
F. Kong ◽  
R. Kovacevic

A three-dimensional (3D) numerical model is developed by using control volume method to analyze the effects of the electron beam scanning speed on the temperature distribution and fluid flow of the liquid phase in the electron beam melting® (EBM) of Ti-6Al-4V powder. The numerical calculations are performed by Fluent codes, in which thermal analyses with and without considering fluid flow in the molten pool are compared. A series of experiments are performed with an Electron Beam Melting® machine to verify the numerical accuracy. Compared to thermal analysis without considering convection in the molten pool, a closer numerical prediction of geometrical size of molten pool to the experimental data can be achieved by using thermal and fluid flow modeling. The difference between the melt pool geometry in the two models is due to the consideration of the effects of the outward flow in the fluid flow model caused by surface tension.


2019 ◽  
Vol 26 ◽  
pp. 202-214 ◽  
Author(s):  
Yufan Zhao ◽  
Yuichiro Koizumi ◽  
Kenta Aoyagi ◽  
Daixiu Wei ◽  
Kenta Yamanaka ◽  
...  

1969 ◽  
Vol 9 (03) ◽  
pp. 293-300 ◽  
Author(s):  
J.E. Varnon ◽  
R.A. Greenkorn

Abstract This paper reports an investigation of unstable fingering in two-fluid flow in a porous medium to determine if lambda the dimensionless finger width, is unique For a viscous finger A is the ratio of finger width to the distance between the tips of the two trailing fingers adjacent to the leading finger. For a gravity finger lambda is defined as the ratio of finger width, to "height" of the medium perpendicular to hulk flow. This work confirms previous experiments and existing theory that for viscous fingering lambda approaches a value of 0.5 with increasing ratio of viscous to interfacial force. However, for a given fluid pair and given, medium, this ratio can he increased only by increasing the, velocity. Experiments on gas liquid systems show that the asymptotic value of lambda with velocity is not always 0.5. Apparently, for gas-liquid systems, the influence of the interfacial force cannot always he eliminated by increasing the velocity. For such systems lambda is a function of fluid pair and media permeability. If the gravity force normal to the hulk permeability. If the gravity force normal to the hulk flow is active, it damps out the viscous fingers except for an underlying or overlying finger. The dimensionless width of this gravity finger strongly depends on velocity and height of the medium, as well as the fluid and media properties. The existing experiments and theories are reviewed and the gravity, stable, and viscous flow regimes are described in view of these experiments and theories. The existence of a gravity-dominated unstable regime, a gravity-viscous balanced stable regime, and a viscous-anminated regime was demonstrated experimentally by increasing flow velocity bin a rectangular glass head model. Asymptotic values of the dimensionless finger width were determined in various-sized Hele-Shaw models with gravity perpendicular and parallel to flow. The dimensionless perpendicular and parallel to flow. The dimensionless finger width lambda was determined as a function of applied force, flow resistance, and fluid properties. The results are interpreted dimensionally. Some comments are made concerning possible scaling and meaningful extensions of theory to describe these regimes in three-dimensional flow. Previous description of unstable two-fluid flow in porous media is mainly restricted to studies of viscous-dominated instability. The direction of this study is to provide data and understanding to consider the more realistic problem of predicting flow in three dimensions that may result in instabilities that are combinations of all, four flow regimes. Introduction The unstable flow of two fluids is characterized by interface changes between the fluids as a result of changes in relative forces. In a given porous medium and for a given fluid pair the gravity force dominates flow at low displacement velocities. As the velocity increases the viscous forces begin to affect flow significantly, and eventually there is a balance between effects of the gravity and viscous forces. As velocity increases further, the viscous force dominates flow. In the plane parallel to gravity, four flow regimes result as the velocity is increased: a gravity-induced stable flow regime; a gravity-dominated unstable flow regime; a stable regime resulting from a balance between gravity and viscous forces; and a viscous-induced unstable flow regime. The gravity-induced stable regime is represented schematically in Fig. 1a. This general flow pattern persists with the displacing fluid contacting all of persists with the displacing fluid contacting all of the in-place fluid until the interface becomes parallel to the bulk flow. At this velocity a gravity finger forms, and the interface, is unstable in that the length of the gravity finger grows and the fluid behind the nose of the finger is practically nonmobile because of the small pressure gradient along the finger. The gravity-dominated unstable flow is shown schematically in Fig. 1b. As the injection rate is increased, the gravity finger thickens, perhaps until it spans the medium creating a stable interface where all of the in-place, fluid is again mobile. This regime would, not occur in the absence of gravity. It occurs due to the counter effects of the gravity and viscous forces (Fig. 1c). As the velocity of the displacing fluid increases, the viscous forces dominate, and, the interface breaks into viscous fingers (Fig. 1d). SPEJ p. 293


Metals ◽  
2018 ◽  
Vol 8 (7) ◽  
pp. 486 ◽  
Author(s):  
Xiongfeng Ruan ◽  
Qi Zhou ◽  
Leshi Shu ◽  
Jiexiang Hu ◽  
Longchao Cao

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