Numerical simulation of the effects of bypass current on droplet transfer during AZ31B magnesium alloy DE-GMAW process based on FLUENT

Zhang, Saiyu; Ma, Guohong; Peng, Xiaofei; Xiang, Yue

doi:10.1007/s00170-016-9438-y

Cited by 14 publications

(5 citation statements)

References 11 publications

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“…Figure 12 illustrates the mechanical model of the droplet growing at the root of welding wire. According to the static equilibrium theory [23], the droplet is subjected to gravity G, surface tension F s , plasma ow force F p and electromagnetic force F em .…”

Section: Formation Mechanism Of Different Droplet Transfer Modesmentioning

confidence: 99%

Effect of pulse current on droplet transfer behavior and weld formation of 304 stainless steel in local dry underwater MIG welding

Liao¹,

Zhang²,

Li³

et al. 2022

Preprint

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In this study, 304 stainless steel which widely used in the industrial field due to its excellent thermostability, corrosion resistance and welding performance, was welded using local dry underwater pulse metal inert-gas (LDU-PMIG) welding technology. The effect of different pulse peak currents on droplet transfer behavior and weld formation was studied. The results show that short circuit transfer, globular transfer, and projected transfer could be observed in the LDU-PMIG process. With the peak current of 240A, the droplet transfer mode was short circuit transfer and globular transfer, the weld formation was irregular with large particle spatters around the weld. With the peak current increased to 260A, the droplet transfer mode changed into the globular transfer, and the weld formation quality was improved. With the peak current of 280A, the droplet transfer mode was projected transfer, the weld formation was satisfied with few spatter, and the coefficient of weld formation was the largest, projected transfer was the most stable mode. With the increase of the peak current from 300A to 320A, the droplet transfer mode did not change, but the instability of the welding arc resulted in poor weld formation with serious spatters and undercuts.

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Section: Formation Mechanism Of Different Droplet Transfer Modesmentioning

confidence: 99%

Effect of pulse current on droplet transfer behavior and weld formation of 304 stainless steel in local dry underwater MIG welding

Liao¹,

Zhang²,

Li³

et al. 2022

Preprint

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show abstract

“…Thus, the effects of very few processing variables on microstructural and mechanical properties of Mgalloy welds have been investigated. There is the need to use computational modelling coupled with numerical simulations to understand the overarching effects of these parameters [85,[112][113][114]. This method will be faster, less expensive, and not lengthy as the Edisonian approach.…”

Section: Summary On Fusion Welding Of Mg Alloysmentioning

confidence: 99%

Welding of magnesium and its alloys: an overview of methods and process parameters and their effects on mechanical behaviour and structural integrity of the welds

et al. 2021

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An overview of welding methods and process parameters and its effects on mechanical behaviour and structural integrity of magnesium and its alloys are discussed. These alloys are less dense and beneficial structural alloys for improved energy efficiency, eco-friendliness and driver of circular economic model for sustainable design and innovative ecosystem. While the application of Mg-alloys is projected to increase, understanding the mechanical behaviour and structural integrity of welded joints are critical. Thus, fusion and solid-state welding processes of these alloys are discussed with emphasis on mechanical characterization. Laser welding is the most effective fusion welding technique for most Mg alloys whereas, the predominant solid-state method is friction stir welding. The importance of process variables such as heat inputs, welding velocity (speed) and post weld treatments on the microstructural evolution, on mechanical and physical properties of the distinct zones of the weld joints are described. The weldment is the most susceptible to failure due to phase transformation, defects such as microporosity and relatively coarse grain sizes after solidification. The implication of the design of quality weld joints of Mg alloys are explored with areas for future research directions briefly discussed.

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“…Due to its special technical characteristics such as low heat input, it has been successfully applied to metal droplet control [13,14], dissimilar metals joining [15,16], and metal additive manufacturing [17,18]. Furthermore, its process characteristics have attracted wide attention in the field of research and engineering in recent years [19][20][21]. On the other hand, Sridhar et al [22] explored the influence of process parameters on the steel joint by double-sided continuous welding.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Investigation of the Thermal and Force Regulation Mechanism of Bypass Coupling Double-Sided Arc Welding Based on 6061 Aluminum Alloy

Zhang,

Wang,

Miao

et al. 2024

Coatings

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In this study, 6061 aluminum alloy was proposed for welding using bypass coupling double-sided arc welding (BCO-DASW) to further improve its welding quality and efficiency. To gain insight into the thermal and force regulation mechanism of the BCO-DASW of 6061 aluminum alloy, the dynamic effects of the high-temperature plasma inside the arc with various parameters were fully compared and investigated through the combined method of the physical experiment and the numerical simulation. The thermal flow field of the hybrid arc was analyzed numerically. Furthermore, its working adaptability and mechanical behaviors were studied experimentally. The results show that a single penetration of the 6 mm sheets can be achieved without visible defects when the center offset of the arcs is within 3 mm on both sides of the base metal during BCO-DASW. Through the thermal analysis, it was found that, compared with the MIG process, the introduction of the bypass arc lead to a temperature decrease at the bottom of the hybrid arc due to energy redistribution. Furthermore, through the kinetic analysis, it was found that not only could the level of arc pressure be reduced, but also the action range of the arc pressure could be regulated up to 4.6 mm. The thermal force regulation mechanism worked together to enhance the stability of the molten pool and achieves good joint strength during the BCO-DASW of 6061 aluminum alloy. This research not only has great significance in further improving the welding quality and efficiency of aluminum alloy, but also deeper understanding of the energy regulation mechanism during aluminum alloy welding.

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Numerical simulation of the effects of bypass current on droplet transfer during AZ31B magnesium alloy DE-GMAW process based on FLUENT

Cited by 14 publications

References 11 publications

Effect of pulse current on droplet transfer behavior and weld formation of 304 stainless steel in local dry underwater MIG welding

Effect of pulse current on droplet transfer behavior and weld formation of 304 stainless steel in local dry underwater MIG welding

Welding of magnesium and its alloys: an overview of methods and process parameters and their effects on mechanical behaviour and structural integrity of the welds

Experimental and Numerical Investigation of the Thermal and Force Regulation Mechanism of Bypass Coupling Double-Sided Arc Welding Based on 6061 Aluminum Alloy

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