Numerical Analysis of Heat Transfer and Fluid Flow in Keyhole Plasma Arc Welding

Zhang, Tao; Wu, Chuansong; Feng, Yanhui

doi:10.1080/10407782.2011.616851

Cited by 47 publications

(15 citation statements)

References 11 publications

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“…Studies [31][32] show that a combined double-ellipsoidal and conical volumetric heat source produce results that agree with experiments better if the keyhole effect cannot be ignored. As stated earlier, deep keyholes are avoided in the PAW-based WAAM process to ensure the success of deposition.…”

Section: Arc Heat Source Modelmentioning

confidence: 85%

“…According to the camera observation of the wire melting and transfer to the molten pool, the spherical region was chosen to be 0.6mm radius, the initial velocity was about 0.1m/s in the negative Z direction. And the temperature was chosen to be 2600K according to the results in literature [29][30][31].…”

Section: Mass Input Modelmentioning

confidence: 99%

“…Sun [30] used the molten pool surface deformation equation to calculate the real-time keyhole evolution in PAW process. Zhang [31] used VOF method to calculate the keyhole free surface. The coupling of the arc plasma, molten pool and keyhole are considered.…”

Section: Introductionmentioning

confidence: 99%

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Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing

Bai

Colegrove

Ding

et al. 2018

International Journal of Heat and Mass Transfer

193

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A three-dimensional numerical model has been developed to investigate the fluid flow and heat transfer behaviors in multilayer deposition of plasma arc welding (PAW) based wire and arc additive manufacture (WAAM). The volume of fluid (VOF) and porosity enthalpy methods are employed to track the molten pool free surface and solidification front, respectively. A modified double ellipsoidal heat source model is utilized to ensure constant arc heat input in calculation in the case that molten pool surface dynamically changes. Transient simulations were conducted for the 1 st , 2 nd and 21 st layer depositions. The shape and size of deposited bead and weld pool were predicted and compared with experimental results. The results show that for each layer of deposition the Marangoni force plays the most important role in affecting fluid flow, conduction is the dominant method of heat dissipation compared to convection and radiation to the air. As the layer number increases, the length and width of molten pool and the width of deposited bead increase, whilst the layer height decreases. However these dimensions remain constant when the deposited part is sufficiently high. In high layer deposition, where side support is absent, the depth of the molten pool at the rear part is almost flat in the Y direction. The profile of the deposited bead is mainly determined by static pressure caused by gravity and surface tension pressure, therefore the bead profile is nearly circular. The simulated profiles and size dimensions of deposited bead and molten pool were validated with experimental weld appearance, cross-sectional images and process camera images. The simulated results are in good agreement with experimental results.

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Section: Arc Heat Source Modelmentioning

confidence: 85%

Section: Mass Input Modelmentioning

confidence: 99%

See 1 more Smart Citation

Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing

Bai

Colegrove

Ding

et al. 2018

International Journal of Heat and Mass Transfer

193

View full text Add to dashboard Cite

show abstract

“…According to Maxwell's electromagnetic theory, the electromagnetic forces [29] are expressed in a Cartesian coordinate system as follows:…”

Section: Momentum Conservation Equationmentioning

confidence: 99%

Prediction of the Weld Pool Stability by Material Flow Behavior of the Perforated Weld Pool

et al. 2020

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This article presents the application of a computational fluid dynamics (CFD) finite volume method (FVM) model for a thermo-mechanical coupling simulation of the weld pool used in variable polarity plasma arc welding (VPPAW). Based on the mechanism of the additional pressure produced through self-magnetic arc compression and the jet generated from mechanical plasma arc compression, and considering the influence of arc height and keyhole secondary compression on arc pressure, a three-dimensional transient model of variable polarity plasma arc (VPPA) arc pressure was established. The material flow behaviors of the perforated weld pools were studied. The results show that three kinds of flow behavior existed in the perforation weld pools and it is feasible to predict the weld pool stability by the material flow behaviors of the perforated weld pools. The weld pools can exist stably if the material flow in the bottom of the perforated weld pools can form confluences with moderate flow velocities of 0.45 m/s, 0.55 m/s and 0.60 m/s. The weld pools were cut when the material flowed downward and outward with the maximum velocity of 0.70 m/s, 0.80 m/s. When the maximum material flow velocity was 0.40 m/s, the weld pool collapsed downward under the action of larger gravity. The thermo-mechanical coupling model was verified by the comparison of the simulation and experimental results.

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“…In contrast, some other studies (Lago et al, 2004;Tanaka et al, 2004;Li et al, 2017) simulated the heating process of the solid material but ignoring the phase changing or liquid flow. Meanwhile, part of models (Wu et al, 2009;Zhang et al, 2011) introduced the pressure and thermal intensity generated by the electric arc plasma through specific boundary conditions to achieve the consideration of the arc. Thus, the model only included the solid region and the electric arc plasma itself was ignored.…”

Section: Introductionmentioning

confidence: 99%

Multi-Physics Modeling of Steel Ingot Melting by Electric Arc Plasma and its Application to Electric Arc Furnace

et al. 2020

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Arc melting is one of the commonly-used melting methods in modern material manufacturing. The present study established a numerical model coupling the electric arc plasma, solid melting, and liquid flow together to simulate the steel ingot melting process using the electric arc. The direct current electric arc behavioral characteristics with varying arc length generated by the moving electrode were analyzed based on the validated model. The effects of both the initial arc length and the dynamic electrode movement on the steel ingot melting efficiency were studied. A potential method was also proposed to apply the established model in simulating the electric arc furnace scrap melting. The study reveals that a reasonable and stable arc length can provide higher instantaneous heat flux and current density and reduce the arc dissipation, meanwhile balance the electrode consumption rate and melting efficiency to achieve the highest economic benefit. In addition, the dynamic electrode movement during the melting process maintains the original arc performance near the ingot top surface, which also results in a positive impact on the melting efficiency.

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Numerical Analysis of Heat Transfer and Fluid Flow in Keyhole Plasma Arc Welding

Cited by 47 publications

References 11 publications

Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing

Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing

Prediction of the Weld Pool Stability by Material Flow Behavior of the Perforated Weld Pool

Multi-Physics Modeling of Steel Ingot Melting by Electric Arc Plasma and its Application to Electric Arc Furnace

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