Numerical analysis of weld pool behaviors in plasma arc welding with the lattice Boltzmann method

Cai, Junjie; Feng, Yanhui; Zhou, Junjie; Li, Yan; Zhang, Xinxin; Chen, Wu

doi:10.1016/j.ijthermalsci.2017.10.026

Cited by 21 publications

(3 citation statements)

References 52 publications

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“…Besides, the keyhole channel is curved backward [20,21], which also has great effect on the heat source distribution. The combined volume heat source models were used in previous numerical simulation [22][23][24]. A deviation parameter of the volume heat source center was introduced to considered the thermal effect of the keyhole deviation [25].…”

Section: Introductionmentioning

confidence: 99%

A novel electrode-arc-weld pool model for studying the keyhole formation in the keyhole plasma arc welding process

Tashiro

Hua

et al. 2019

J. Phys. D: Appl. Phys.

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A novel electrode-arc-weld pool model considering the influence of the backside keyhole deviation on the heat source distribution, the influence of the keyhole constraint on the arc pressure and the keyhole geometry dependent plasma shear stress, is developed to study the keyhole formation in the KPAW process. The numerical and experimental results show that: the keyhole depth increases very quickly at first, then smoothly, and then quickly again. In the blind keyhole stage, the arc pressure deepens the keyhole. The plasma shear stress facilitates the fluid flow along the rear keyhole wall and decreases the curvature of the keyhole. The process between the weld pool penetration and the keyhole penetration is defined as the blasting penetration stage, in which the molten bridge under the arc is quickly broken. The pressure balance and mass conservation mechanisms are proposed to be responsible for the blasting penetration. The low melting temperature, low surface tension and bottom surface deformation promote the blasting penetration, while the high thermal conductivity suppresses the blasting penetration. In the penetrated keyhole stage, two contrary convective eddies are found inside the weld pool. At the top surface of the weld pool, the molten metal flows upward and backward near the keyhole, but obviously flows forward at the rear part of the weld pool. At the bottom surface of the weld pool, the molten metal flows downward and backward.

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Section: Introductionmentioning

confidence: 99%

A novel electrode-arc-weld pool model for studying the keyhole formation in the keyhole plasma arc welding process

Tashiro

Hua

et al. 2019

J. Phys. D: Appl. Phys.

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“…Researchers quantitatively described the formation trend of weld hump under different welding parameters, and predicted the formation of weld hump [3]. Additionally further analyzed the formation mechanism of the hump in the fusion zone from the perspective of fluid movement, that is, increase the welding current to accelerate the penetration of the molten pool and improve energy efficiency [4]. At the same time, the research results show that the thermal expansion of liquid metal is the main reason for the bulging of the surface of the molten pool [5].…”

Section: Introductionmentioning

confidence: 99%

Analysis of Controlled Driving and Spreading Behavior of Molten Pool in Cold Metal Transfer

et al. 2022

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The controlled short-circuit transfer is used to control the heat input of the molten pool and the base metal in the cold metal transfer welding process, including droplet formation, droplet transfer and molten pool flow. Based on the influence of arc pressure on the surface of the molten pool, droplet impact and residual energy on the flow behavior of the molten pool, this research proposes the arc pressure driving model, the droplet impact driving model and the residual energy transfer model on the molten pool surface respectively, and on this basis, a theoretical model of controlled driving and spreading of the cold metal transition bath is proposed. The theoretical relationship between the surface shape of the keyhole and the driving force, and the relationship between the surface shape of the molten pool and the welding current are established. The model accurately predicts the formation width and contact angle of the molten pool in a specific interval, which can better control the welding process and geometry.

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“…For simplicity, some researchers neglected plasma arc in calculations but just constructed an equivalent heat source model [7,8] in workpiece to predict the temperature development and weld pool morphology. Feng et al [9,10] developed a heat source model with a Lattice Boltzmann method (LBM) to study the weld pool behaviors in PAW. In order to reveal the keyhole effect between plasma arc and liquid metal, some researchers apply a two-phase flow model to calculate their interaction.…”

Section: Introductionmentioning

confidence: 99%

A Convenient Unified Model to Display the Mobile Keyhole-Mode Arc Welding Process

Wang

2020

Applied Sciences

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Keyhole-mode plasma arc welding (PAW) has a good prospect in the manufacturing industry. Unified models of plasma arc and workpiece help to reveal the physical mechanism in PAW for a better application. Previous unified models either deal with a constant keyhole situation or take too much computational time to display the dynamic keyhole process with a two-phase flow method. In view of the convenience for industrial application as well as good accuracy, a convenient unified model was developed to describe the mobile keyhole-mode PAW. With a simplified technique, the multiphase heat and force effect between plasma arc and workpiece was turned into a single-phase problem at each individual domain. Thus, it takes less computational time than previous unified models. The temperature field and weld pool during the mobile keyhole-mode PAW process were revealed, the arc flow and pool flow were displayed and the electric potential was predicted. The experiment was conducted on a stainless-steel plate, and the weld pool image and the measured arc pressure agree well with the calculated result. The calculated electric potential drop also coincides with the experiment. The model provides a convenient and accurate method to display the mobile keyhole-mode arc welding process.

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Numerical analysis of weld pool behaviors in plasma arc welding with the lattice Boltzmann method

Cited by 21 publications

References 52 publications

A novel electrode-arc-weld pool model for studying the keyhole formation in the keyhole plasma arc welding process

A novel electrode-arc-weld pool model for studying the keyhole formation in the keyhole plasma arc welding process

Analysis of Controlled Driving and Spreading Behavior of Molten Pool in Cold Metal Transfer

A Convenient Unified Model to Display the Mobile Keyhole-Mode Arc Welding Process

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