The Effect of Groove Shape on Molten Metal Flow Behaviour in Gas Metal Arc Welding

Ebrahimi, Amin; Babu, Aravind; Kleijn, Chris R.; Hermans, M.J.M.; Richardson, I.M.

doi:10.3390/ma14237444

Cited by 16 publications

(6 citation statements)

References 57 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…User-defined functions (UDFs) programmed in the C programming language were developed to implement the absorptivity model, source and sink terms in the momentum and energy equations as well as the surface tension model in the simulations. As shown in our previous works [3,8,9,52,53], the numerical grid cell spacing should be chosen to have at least 35 cells in the melt pool region along its width. Accordingly, hexahedral cells were used to discretise the computational domain with minimum cell spacing of 50 µm for cases in batch 1 and 2 (CO 2 and Nd:YAG welds, melt-pool widths of about 1500 µm), and 3 µm for cases in batch 3 (continuous wave fibre laser welds, melt-pool widths of about 100 µm), as shown in figure 4.…”

Section: Numerical Implementationmentioning

confidence: 99%

The influence of laser characteristics on internal flow behaviour in laser melting of metallic substrates

Ebrahimi,

Sattari,

Bremer

et al. 2022

Preprint

Self Cite

View full text Add to dashboard Cite

The absorptivity of a material is a major uncertainty in numerical simulations of laser welding and additive manufacturing, and its value is often calibrated through trial-and-error exercises. This adversely affects the capability of numerical simulations when predicting the process behaviour and can eventually hinder the exploitation of fully digitised manufacturing processes, which is a goal of "industry 4.0". In the present work, an enhanced absorption model that takes into account the effects of laser characteristics, incident angle, surface temperature, and material composition is utilised to predict internal heat and fluid flow in laser melting of stainless steel 316L. Employing such an absorption model is physically more realistic than assuming a constant absorptivity and can reduce the costs associated with calibrating an appropriate value. High-fidelity three-dimensional numerical simulations were performed using both variable and constant absorptivity models and the predictions compared with experimental data. The results of the present work unravel the crucial effect of absorptivity on the physics of internal flow in laser material processing. The difference between melt-pool shapes obtained using fibre and CO 2 laser sources is explained, and factors affecting the local energy absorption are discussed.

show abstract

Section: Numerical Implementationmentioning

confidence: 99%

The influence of laser characteristics on internal flow behaviour in laser melting of metallic substrates

Ebrahimi,

Sattari,

Bremer

et al. 2022

Preprint

Self Cite

View full text Add to dashboard Cite

show abstract

“…Wu et al developed numerical models for the twin-wire [24] and hybrid GMAW process [25] using a comprehensive CFD-based simulation. The mechanisms in uencing the molten pool ow were investigated and simulated in various conditions of driving forces [26], undercut formation [27], transverse magnetic eld [28], arc interactions [29], groove shape [30], double-sided [31], double-shielded [32], and double-pulsed [33] GMAW. The improvement of numerical models is still ongoing, especially in the topics such as wire-arc additive manufacturing (WAAM) [34,35], where new industrial applications are emerging.…”

Section: Introductionmentioning

confidence: 99%

Effect of workpiece vibration frequency on heat distribution and material flow in the molten pool in tandem-pulsed gas metal arc welding

Hamed Zargari,

Ito,

Sharma

2023

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Versatility, high deposition rate, ne quality, and low equipment cost are known features of the tandem-pulsed gas metal arc welding (TP-GMAW) process. Concurrently, vibration-assisted welding has been considered one of the trends in developing advanced industrial concepts. This study presents a three-dimensional model of the TP-GMAW process to investigate heat transfer and material ow. The competition between the heat distribution beneath the surface and the physical movement caused by the workpiece sine-mode vibration are traced and discussed to understand how the penetration shape change was determined. It is found that applying the vibration extends the heat distribution along the welding direction beneath the weld pool surface, and this trend increases with increasing vibration frequency and effective heat input. In contrast, the heat extending is minimum in the sample without vibration having the highest heat input. This inconsistency can be explained by the physical movement of material in a molten pool due to the workpiece vibration. The vibration also changes the material ow from the surface to the depth in the central rear areas, although it follows an opposite direction in the sample without vibration. Thus, the material ow is vital in improving the penetration shape. DeclarationsAcknowledgements: The investigation results from a joint research program between the Joining and Welding

show abstract

“…The research findings revealed that the presence of the groove promotes smoother flow within the weld pool, leading to inadequate mixing between the filler metal and the base metal. Ebrahimi et al [11]. proposed a computational model that aims to describe the behavior of the melt pool in root-pass gas metal arc welding (GMAW).…”

Section: Introducementioning

confidence: 99%

Numerical Simulations and Experimental Verification of T-Structure Welding Deformation Using the Step-by-Step Loading Inherent Strain Method

Wang

Miao

et al. 2023

Metals

View full text Add to dashboard Cite

The existing inherent strain method is improved in this paper to address the shortcomings of the existing inherent strain method in the process of loading inherent strain. Unlike the traditional inherent strain method, which uses one-step loading inherent strain for each weld seam for one-time elastic calculation, the improved inherent strain method uses step-by-step loading inherent strain for each weld seam for multiple elastic calculations to predict welding deformation. The step-by-step loading inherent strain method (SBS-ISM) is more in line with the actual welding deformation generation process. Firstly, the local finite element model of the T-joint was used to analyze the welding deformation and extract the inherent strain by using the thermal elastic–plastic finite element method (TEP-FEM). Subsequently, the one-step loading inherent strain method (OS-ISM) and the step-by-step loading inherent strain method (SBS-ISM) were used to predict the welding deformation for the same local finite element model, respectively. The comparative results showed that the trend and magnitude of welding deformation calculated using SBS-ISM was much closer to those calculated using TEP-FEM. The OS-ISM and SBS-ISM were used to predict the welding deformation of the backward centrifugal fan impeller under different welding sequences, respectively. By comparing the welding deformation results calculated using the two inherent strain methods with the experimental results, it was demonstrated that the step-by-step loading inherent strain method (SBS-ISM) provides more accurate and reliable predictions of welding deformation for large and complex thin-walled T-shaped structural components compared to the one-step loading inherent strain method (OS-ISM).

show abstract

The Effect of Groove Shape on Molten Metal Flow Behaviour in Gas Metal Arc Welding

Cited by 16 publications

References 57 publications

The influence of laser characteristics on internal flow behaviour in laser melting of metallic substrates

The influence of laser characteristics on internal flow behaviour in laser melting of metallic substrates

Effect of workpiece vibration frequency on heat distribution and material flow in the molten pool in tandem-pulsed gas metal arc welding

Numerical Simulations and Experimental Verification of T-Structure Welding Deformation Using the Step-by-Step Loading Inherent Strain Method

Contact Info

Product

Resources

About