Development of avocado shape heat source model for finite element based heat transfer analysis of high-velocity arc welding process

Mondal, Arpan Kumar; Kumar, Bikash; Bag, Swarup; Nirsanametla, Yadaiah; Biswas, Pankaj

doi:10.1016/j.ijthermalsci.2021.107005

Cited by 19 publications

(2 citation statements)

References 26 publications

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“…Gaussian double ellipsoid heat resource model shown in Fig. 4, is applied to describe the heat distribution of conventional MAG welding [27][28][29][30] . Set the half-axis parameters of the double ellipsoid to be (a, b, c 1 , c 2 ) , and the proportions of heat input in the front and back hemispheres are f f and f r respectively.…”

Section: Resultsmentioning

confidence: 99%

Heat source modeling, penetration analysis and parametric optimization of super spray MAG welding

Xia

2023

Sci Rep

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Main drives, cutterheads and other critical components of tunnel shield machines require welding with thick plates that leave roots over 5 mm. Full penetration welds cannot be achieved by conventional Pulsed MAG welding methods. This article introduces Super Spray MAG Welding technology and investigates its penetrating regularities and mechanisms through high-speed camera images, finite element simulation, and microstructural analysis. An optimal welding procedure was generated using a combination of Genetic Algorithm and Back Propagation Neural Network. The data show that Super Spray MAG arc exhibits greater concentration and stability than traditional MAG arc, marking its strong qualities in emitting high-energy beams. The morphological solidification pattern of the molten pool closely matches the FEM simulation results of the composite Gaussian surface heat source model and peak linear attenuation Gaussian cylinder heat source. The welding current mainly affects the penetration of the weld, followed by the extension of the wire, and lastly the welding speed. Increasing the welding current can transition droplet transfer from globular to spray, as well as alter microstructure development and mechanical characteristics. Suggested parameters for penetrating the 5 mm root were put forward. The BPNN-GA model established can effectively predict weld formation, and points out the optimal welding parameters.

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Section: Resultsmentioning

confidence: 99%

Heat source modeling, penetration analysis and parametric optimization of super spray MAG welding

Xia

2023

Sci Rep

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“…For this reason, an accurate knowledge of the thermomechanical aspects featuring the joining procedure and its evolution during the process execution is required with the aim to identify, control and minimize problems to achieve the desired and reliable outputs. Besides, considering the important role of the FE modeling as predictive tool, the research focused on welding process made significant efforts both in the experimental and numerical fields investigating several aspects of the joining process: distortion, residual stresses [5,6], clamping system [7,8], temperature fields, heat source modelling [9,10]. J.J. Xu et al [11] carried out an uncoupled 3D thermal and mechanical analysis by SYSWELD, a commercial software code for welding simulations, to predict and analyse temperature and residual stress during a single weld bead deposition on AISI 316L austenitic steel by Tungsten Inert Gas (TIG) welding.…”

Section: Introductionmentioning

confidence: 99%

Finite element modelling and experimental validation of microstructural changes and hardness variation during gas metal arc welding of AISI 441 ferritic stainless steel

Caruso

Imbrogno

2022

Int J Adv Manuf Technol

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Grain growth and hardness variation occurring in high temperature Heat Affected Zone (HAZ) during the welding processes are two thermal dependant aspects of great interest for both academic and industrial research activities. This paper presents an innovative Finite Element (FE) model capable to describe the grain growth and the hardness decrease that occur during the Gas Metal Arc Welding (GMAW) of commercial AISI 441 steel. The commercial FE software SFTC DEFORM-3D TM was used to simulate the GMAW process and a user subroutine was developed including a physical based model and the Hall-Petch (H-P) equation to predict grain size variation and hardness change. The model was validated by comparison with the experimental results showing its reliability in predicting important welding characteristics temperature dependant. The study provides an accurate numerical model (i.e. user subroutine, heat source fitting, geometry,…) able to successfully predict the thermal phenomena (i.e. coarsening of the grains and hardening decrease) that occur in the HAZ during welding process of ferritic stainless steel.

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Numerical and experimental validation of gas metal arc welding on AISI 441 ferritic stainless steel through mechanical and microstructural analysis

Caruso

Umbrello

2022

Int J Adv Manuf Technol

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Residual stresses and strains, distortions, heat-affected zone (HAZ), grain size changes and hardness variation during gas metal arc welding (GMAW), are fundamental aspects to study and control during welding processes. For this reason, numerical simulations of the welding processes represent the more frequently used tool to better analyse the several aspects characterizing this joining process with the aim to reduce lead time and production costs. In the present study, an uncoupled 3D thermo-mechanical analysis was carried out by two commercial finite element method (FEM) software to model an experimental single bead GMAW of AISI 441 at different processes set-up. The experimental HAZ and measured temperatures were used to calibrate the heat source of both the used numerical codes, then a validation phase was done to test the robustness of the two developed analytical procedures. One software was used to predict the residual stresses and strains and the distortions of the welded components, while in the second software, a user routine was implemented, including a physical based model and the Hall-Petch (H-P) equation, to predict grain size change and hardness evolution, respectively. The results demonstrate that the predicted mechanical and microstructural aspects agree with those experimentally found showing the reliability of the two codes in predicting the thermal phenomena characterizing the HAZ during the analysed welding process.

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Development of avocado shape heat source model for finite element based heat transfer analysis of high-velocity arc welding process

Cited by 19 publications

References 26 publications

Heat source modeling, penetration analysis and parametric optimization of super spray MAG welding

Heat source modeling, penetration analysis and parametric optimization of super spray MAG welding

Finite element modelling and experimental validation of microstructural changes and hardness variation during gas metal arc welding of AISI 441 ferritic stainless steel

Numerical and experimental validation of gas metal arc welding on AISI 441 ferritic stainless steel through mechanical and microstructural analysis

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