scholarly journals Numerical Analysis and Experimental Verification of Optimum Heat Input in Additive Manufacturing of Aero Ultrathin Blade

2021 ◽  
Vol 2021 ◽  
pp. 1-23
Author(s):  
Shijie Dai ◽  
Miao Gong ◽  
Liwen Wang ◽  
Tao Wang
Keyword(s):  
Heat Transfer ◽  
Additive Manufacturing ◽  
Numerical Analysis ◽  
Heat Source ◽  
Heat Input ◽  
Source Model ◽  
Heat Transfer Model ◽  
Transfer Model ◽  
Heat Source Model ◽  
Blade Repair

Heat input is a crucial factor affecting the quality in blade additive manufacturing repairing. First, a moving heat source model was established, and through numerical analysis and experimental comparison, the optimal geometric parameters of the heat source model for ultrathin blade repair were obtained. Second, a heat transfer model is established based on the optimal heat source model. By analyzing the thermophysical properties of different alloys, the heat input range of the blade was calculated. By heat transfer calculation under different heat inputs, the heat transfer model of blade repair was optimized. Then, a mathematical model of additive height is established. The optimized heat transfer model is used to solve the temperature distribution of the additive section with time under different wire feeding speeds through numerical analysis, which further reduced the heat input range. Third, the experiments are carried out based on the results of numerical analysis. The evolution law of the microstructure and heat input rate of the additive manufacturing zone was revealed, and the optimal heat input parameters were obtained. Under the optimal parameters, the segregation zone disappeared; hence, the test data were close to the base metal, and the additive manufacturing zone achieved better quality. The results and methods are of great guiding significance for the optimization design in additive manufacturing repair of the aero blades. The study also contributes to carrying out a series of research on heat transfer of ultrathin nickel-based alloy welding.

scholarly journals Modeling of additive height and numerical analysis of cooling parameters for aero blade remanufacturing

2021 ◽  
Vol 12 (2) ◽  
pp. 803-818
Author(s):  
Miao Gong ◽  
Shijie Dai ◽  
Tao Wang ◽  
Liwen Wang
Keyword(s):  
Heat Transfer ◽  
Mathematical Model ◽  
Numerical Analysis ◽  
Cooling Effect ◽  
Transfer Model ◽  
Factors Affecting ◽  
Coupled Heat Transfer ◽  
Blade Repair ◽  
Geometric Morphology ◽  
The Mathematical Model

Abstract. Additive remanufacturing height and matching cooling parameters are the key factors affecting blade repair quality. First, the mathematical model of the single additive remanufacturing repair height and wire-feeding speed was established, the solution method was proposed and the numerical solution was obtained, and the validity of the model was verified by experiments. Then, based on the calculation results of a single additive remanufacturing repair, the geometric morphology of the cross section under double additive remanufacturing repair was analyzed, and the mathematical model was established. Second, based on the optimal parameters obtained by numerical analysis and the mathematical model, the fluid structure coupling heat transfer model of “blade fixture” for base channel cooling was established. The cooling effect of the typical section under different initial temperatures and different flow rates was calculated, and the coupled heat transfer in the process of blade remanufacturing was explained by the mechanism. Third, through the comparative analysis of the cooling effect, optimal cooling parameters of double additive remanufacturing repair were obtained, and the model of coupled heat flow was verified by experiment. The results showed that the mathematical model of additive remanufacturing height is effective for studying the thermal cycle and cooling effect of welding, and the cooling parameters obtained by numerical analysis can effectively guarantee the quality of double additive remanufacturing of blade repair.

Numerical Analysis of Heat-transfer Model of Mircrowave Sintering for Ceramics Composites with Heat Conduction Phases

2009 ◽  
Vol 24 (4) ◽  
pp. 864-868 ◽  
Author(s):  
Hong-Shun HAO ◽  
Li-Hua XU ◽  
Yong HUANG ◽  
Zhi-Peng XIE ◽  
Xiao-Meng ZHANG ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Heat Conduction ◽  
Numerical Analysis ◽  
Heat Transfer Model ◽  
Transfer Model

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.

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.

scholarly journals Numerical Analysis of the Influence of Electrode Inclination on Temperature Distribution during GMAW Overlaying

2019 ◽  
Vol 2019 ◽  
pp. 1-13 ◽  
Author(s):  
Jerzy Winczek ◽  
Marek Gucwa ◽  
Miloš Mičian ◽  
Krzysztof Makles
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Theoretical Model ◽  
Temperature Distribution ◽  
Numerical Analysis ◽  
Heat Source ◽  
Analytical Description ◽  
Source Model ◽  
Heat Source Model ◽  
Inclination Angles

In the work, an analysis of the influence of electrode inclination on the distribution of temperature in the weld overlaying has been conducted. In the analytical description of the temperature field, a volumetric heat source model with an inclined axis with respect to the direction of surfacing was adopted. In the numerical simulation, the own theoretical model of heat source, algorithm, and program performed in the Borland Delphi environment were used. In the calculation examples, different electrode inclination angles were adopted in relation to the welded plate, in the direction of surfacing, opposite to the direction of welding, and perpendicular to the weld bead.

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