Numerical simulation of temperature field, fluid flow and weld bead formation in oscillating single mode laser-GMA hybrid welding

Gao, Xuesong; Chen, Wu; Goecke, S.-F.; Kügler, H.

doi:10.1016/j.jmatprotec.2016.11.028

Cited by 73 publications

(18 citation statements)

References 16 publications

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“…Inside the pool and directly underneath the arc, the electromagnetic (Lorentz) force due to current flow drove the liquid metal downward. Figure 19(b) shows the fluid flow field and temperature distribution on a transverse cross section during laser-GMA hybrid welding process of lap joint [114]. Similar to the model shown in Fig.…”

Section: Representative Results For Fusionmentioning

confidence: 78%

“…However, these quasi-steady-state weld pool models cannot consider the weld start and stop. On the other hand, transient weld pool models readily consider the weld start, heat source traveling, and weld stop albeit at the expense of high computational time [114].…”

Section: Mathematical Formulationsmentioning

confidence: 99%

“…Representative results of computed temperature and velocity fields computed using (a) quasi-steady-state model[106] (Reprinted with permission from AIP Publishing © 2004), (b) transient model with volume of fluid method for free surface tracking (Reprinted with permission from Elsevier © 2017)[114], and (c) and (d) integrated model of arc plasma and weld pool[107] (Reprinted with permission from Elsevier © 2019)…”

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confidence: 99%

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Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Zhang

Yang

Wei

et al. 2020

Journal of Manufacturing Science and Engineering

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Welding is a major manufacturing process that joins two or more pieces of materials together through heating/mixing them followed by cooling/solidification. The goal of welding manufacturing is to join materials together to meet service requirements at lowest costs. Advanced welding manufacturing is to use scientific methods to realize this goal. This paper views advanced welding manufacturing as a three step approach: (1) pre-design that selects process and joint design based on available processes (properties, capabilities, and costs); (2) design that uses models to predict the result from a given set of welding parameters and minimizes a cost function for optimizing the welding parameters; (3) real-time sensing and control that overcome the deviations of welding conditions from their nominal ones used in optimizing the welding parameters by adjusting the welding parameters based on such real-time sensing and feedback control. The paper analyzes how these three steps depend on process properties/capabilities, process innovations, predictive models, numerical models for fluid dynamics, numerical models for structures, real-time sensing, and dynamic control. The paper also identifies the challenges in obtaining ideal solutions and reviews/analyzes the existing efforts toward better solutions. Special attention and analysis have been given to (1) gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) as benchmark processes for penetration and materials filling; (2) keyhole plasma arc welding (PAW), keyhole-tungsten inert gas (K-TIG), and keyhole laser welding as improved/capable penetrative processes; (3) friction stir welding (FSW) ......

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Section: Representative Results For Fusionmentioning

confidence: 78%

Section: Mathematical Formulationsmentioning

confidence: 99%

mentioning

confidence: 99%

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Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Zhang

Yang

Wei

et al. 2020

Journal of Manufacturing Science and Engineering

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“…A 3D thermo-fluid-mechanical simulation of laser welding by conduction was carried out. It gives qualitatively acceptable results in terms of the velocity field and the evolution of the free surface [32,50]. To study the effect of the solid deformations in the base metal on the fluid flows in the weld pool, a comparison of the results of two simulations was performed.…”

Section: Discussionmentioning

confidence: 99%

New strategy of solid/fluid coupling during numerical simulation of thermo-mechanical processes

Saadlaoui

Delache

Feulvarch

et al. 2020

Journal of Fluids and Structures

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In this study, numerical methods are developed to simulate thermomechanical processes, taking into account both the fluid flows in the molten pool and the deformations of the solid parts. The methods are based on a new strategy of solid/fluid coupling. They allow to simulate the formation of the molten pool by taking into account the fluid flows through both effects of the surface tension ("curvature effect" and "Marangoni effect") and the buoyancy. An ALE approach is used to follow the evolution of the free surface. The effects of the deformations in the base metal on the fluid flows in the molten pool (solid/fluid interaction) is ensured by imposing the velocities of the solid nodes during the thermo-fluid simulation. As an application, a thermo-fluid-mechanical simulation of laser welding is carried out. It is found that the solid/fluid interaction has a minor effect on simulation results.

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“…Xu et al [15] study the residual stress and distortion of a 6061-T6 joint welded by using laser-gas metal arc welding and found that when the residual stress in and surrounding the weld zone was higher, a large distortion would appear in the middle and rear part of the welding joint. Cao et al [16] investigated the temperature field and fluid flow of a lap joint in the laser-GMAW hybrid welding process and found that the temperature gradient of the sheet decreased from the top to the bottom; the fluid flow governed by droplet impingement force was outward, while it became counterclockwise when it was driven by Marangoni force and gravity. Atabaki et al [17] use a numerical finite element model to simulate an aluminum alloys joint prepared using laser arc welding and found that the off-distance between the laser beam and arc source and shoulder width would affect the penetration depth and the geometry of the welding joints.…”

Section: Introductionmentioning

confidence: 99%

Effect of Laser Power on Microstructure and Micro-Galvanic Corrosion Behavior of a 6061-T6 Aluminum Alloy Welding Joints

Zhou

Dai

et al. 2020

Metals

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The 6061-T6 aluminum alloy welding joints were fabricated using gas metal arc welding (GMAW) of various laser powers, and the effect of laser power on the microstructure evolution of the welding joints was investigated. The corrosion behaviors of 6061-T6 aluminum alloy welding joints were investigated in 3.5 wt% NaCl solution using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). The results showed that the micro-galvanic corrosion initiation from Mg2Si or around the intermetallic particles (Al-Fe-Si) is observed after the immersion test due to the inhomogeneous nature of the microstructure. The preferential dissolution of the Mg2Si and Al-Fe-Si is believed to be the possible cause of pitting corrosion. When the laser power reached 5 kW, the microstructure of the welded joint mainly consisted of Al-Fe-Si rather than the Mg2Si at 2 kW. The relatively higher content of Al-Fe-Si with increasing in laser power would increase the volume of corrosion pits.

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Numerical simulation of temperature field, fluid flow and weld bead formation in oscillating single mode laser-GMA hybrid welding

Cited by 73 publications

References 16 publications

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

New strategy of solid/fluid coupling during numerical simulation of thermo-mechanical processes

Effect of Laser Power on Microstructure and Micro-Galvanic Corrosion Behavior of a 6061-T6 Aluminum Alloy Welding Joints

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