Arc physics based heat source modelling for numerical simulation of weld residual stress and distortion

Abstract

Heat source modelling based on weld arc physics has been developed for the more accurate numerical simulation of weld residual stress and distortion. Computational simulation of tungsten inert gas arc plasma based on mathematical modelling of the heat transfer from arc plasma to a welded plate is performed to obtain a more precise temperature distribution during welding. The temperature distribution obtained is used for a large deformation thermal elastic-plastic stress analysis of weld residual stress and distortion. In addition, the effects of welding process conditions on weld residual stress and distortion are examined considering weld penetration with the arc plasma process and verified experimentally. Finally, the effectiveness of arc physics based heat source modelling for numerical simulation of the weld residual stress and distortion is evaluated.

Effect of Welding Process Conditions on Angular Distortion Induced by Bead-on-plate Welding

“…A coupled process-mechanics modeling and simulation technique, which was developed in previous studies, 18,19) was utilized for systematically investigating the effect of welding conditions on the angular distortion induced by GMAW and GTAW. The bead surface and temperature profiles during welding, which are the input data for the thermal elastic-plastic analysis, were calculated through a combined bead formation and thermal conduction analysis with finite difference methods.…”

“…These dimensions are exactly the same as those of previous experiments. 18,19) A fine FE mesh was used around the melted zone to accurately simulate the temperature distribution that determined the thermo-mechanical behavior during welding. The dimensions of the minimum mesh size were 1.0 mm in the longitudinal direction and 0.5 mm in both the transverse and the thickness directions.…”

“…[10][11][12] For example, the double-ellipsoidal moving heat source model 13) enhanced the mathematical theory of heat distribution during welding 3) and the resulting residual stress and deformation. [14][15][16][17] Recently, coupled process-mechanics modeling and simulation techniques for arc welding, such as gas tungsten arc welding (GTAW) 18) and gas metal arc welding (GMAW), 19) have been proposed to accurately calculate the angular distortion induced by bead-on-plate welding. This study examines the effect of welding process and heat input conditions on the angular distortion induced by bead-on-plate welding through a coupled process-mechanics modeling and simulation technique, which was developed based on the experimental results in previous studies.…”

“…This study examines the effect of welding process and heat input conditions on the angular distortion induced by bead-on-plate welding through a coupled process-mechanics modeling and simulation technique, which was developed based on the experimental results in previous studies. 18,19) The calculated relations between welding conditions and angular distortion induced by GTAW and GMAW are plotted against the conventional heat input parameter. To understand the effect of the welding process on angular distortion, the variation in angular distortion due to the existence of the weld reinforcement generated in GMAW is also investigated.…”

Engineering Model of Metal Active Gas Welding Process for Efficient Distortion Analysis

“…12,13) For gas metal arc (GMA) welding, an integrated simulation model between arc plasma, bead formation, thermal conduction, and thermomechanical behaviors was developed. A computational simulation based on electromagnetic thermal fluid modeling of arc plasma provided the distribution of the heat transfer and the arc pressure from the arc plasma to the surface of a welded plate; it also provided the quantity of the mass and heat involved with metal transfer in GMA welding.…”