Variable profile heat source models for numerical simulations of arc welding processes

Farias, Rodrigo Martins; Teixeira, Paulo R.F.; Vilarinho, Louriel Oliveira

doi:10.1016/j.ijthermalsci.2022.107593

Cited by 20 publications

(7 citation statements)

References 34 publications

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“…Volumetric density of heat sources in front and rear quadrants can be expressed as [41]   The Goldak model can be used for numerical simulation of laser welding processes, but it is more suitable simulations of arc welding processes. Generally, it is currently considered to be the most accurate but also the most demanding method for defining heat input to the weld in arc welding processes [16,42].…”

Section: Goldak Heat Source Modelmentioning

confidence: 99%

“…Variable Conical Profile (VCP) and Full Variable Profile (FVP) volumetric heat sources (Figure 10) were developed primarily for numerical simulation of arc welding processes [16]. The concept behind these models is based on the necessity to consider the heat input distribution, as represented by the weld profile, during formulation.…”

Section: Variable Conical Profile and Full Variable Profile Volumetri...mentioning

confidence: 99%

“…The mathematical models provide a way to estimate the heat input during different welding processes. Understanding and controlling the heat input is critical for achieving the real and sufficiently accurate results of numerical simulation of welding processes [13][14][15][16][17].…”

Section: Introductionmentioning

confidence: 99%

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Heat source models for numerical simulation of laser welding processes – a short review

Behúlová,

Babalová

2024

J. Phys.: Conf. Ser.

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In recent decades, numerical modeling and computer simulation have become an integral part of the design, analysis and optimization of fusion welding processes, including laser welding. In general, laser welding processes involve the interaction of multiple physical phenomena, such as thermal, fluid, metallurgical, chemical, mechanical, and diffusion effects, which makes the development of a simulation model difficult and complex. In addition to the geometric characteristics of the parts to be welded, their material properties must be specified in a wide temperature range, as well as the conditions for heat removal to the environment or shielding gas. One of the most complex tasks in the preparation of a simulation model of the laser welding processes consists in the selection of an appropriate heat source model to accurately determine the heat input to the weld. Very important is also the process of experimental verification and validation of the developed simulation models. In this paper, a short examination of significant mathematical heat source models for numerical simulation of laser welding is provided. Numerical analysis of laser welding of sheets made of S650MC steel is accomplished using conical 3D heat source model with the support of the ANSYS code. The effect of geometrical characteristics of the conical volumetric heat source model on the computed width, length, and depth of the weld pool is discussed, along with evaluation of maximum weld pool temperature.

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Section: Goldak Heat Source Modelmentioning

confidence: 99%

Section: Variable Conical Profile and Full Variable Profile Volumetri...mentioning

confidence: 99%

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Heat source models for numerical simulation of laser welding processes – a short review

Behúlová,

Babalová

2024

J. Phys.: Conf. Ser.

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“…Different methods can be used to model the heat input in fusion welding, e.g., moving-point heat sources, line heat sources, surface or volumetric heat sources [ 102 , 103 , 104 , 105 , 106 , 107 , 108 , 109 , 110 , 111 , 112 , 113 , 114 ]. Application of temperatures on the top surface of a weld pool (boundary condition of the first kind) or temperatures to the volume of the molten zone [ 115 ] represent the easiest and fastest ways to model a heat source and to calculate the temperature distribution in welding processes.…”

Section: Theoretical Background and Simulation Modelmentioning

confidence: 99%

Numerical Simulation of Temperature Fields during Laser Welding–Brazing of Al/Ti Plates

Behúlová

Babalová

2023

Materials

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The formation of dissimilar weld joints, including Al/Ti joints, is an area of research supported by the need for weight reduction and corrosion resistance in automotive, aircraft, aeronautic, and other industries. Depending on the cooling rates and chemical composition, rapid solidification of Al/Ti alloys during laser welding can lead to the development of different metastable phases and the formation of brittle intermetallic compounds (IMCs). The effort to successfully join aluminum to titanium alloys is associated with demands to minimize the thickness of brittle IMC zones by selecting appropriate welding parameters or applying suitable filler materials. The paper is focused on the numerical simulation of the laser welding–brazing of 2.0 mm thick titanium Grade 2 and EN AW5083 aluminum alloy plates using 5087 aluminum filler wire. The developed simulation model was used to study the impact of laser welding–brazing parameters (laser power, welding speed, and laser beam offset) on the transient temperature fields and weld-pool characteristics. The results of numerical simulations were compared with temperatures measured during the laser welding–brazing of Al/Ti plates using a TruDisk 4002 disk laser, and macrostructural and microstructural analyses, and weld tensile strength measurements, were conducted. The ultimate tensile strength (UTS) of welded–brazed joints increases with an increase in the laser beam offset to the Al side and with an increase in welding speed. The highest UTS values at the level of 220 MPa and 245 MPa were measured for joints produced at a laser power of 1.8 kW along with a welding speed of 30 mm·s−1 and a laser beam offset of 300 μm and 460 μm, respectively. When increasing the laser power to 2 kW, the UTS decreased. The results exhibited that the tensile strength of Al/Ti welded–brazed joints was dependent, regardless of the welding parameters, on the amount of melted Ti Grade 2, which, during rapid solidification, determines the thickness and morphology of the IMC layer. A simple formula was proposed to predict the tensile strength of welded–brazed joints using the computed cross-sectional Ti weld metal area.

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“…It mostly includes coupled thermal, metallurgical, and mechanical analysis [1][2][3][4][5][6]. In modeling and numerical simulation, the influence of the laser beam on the material during the fusion welding process can be defined by means of different heat source models [7][8][9][10][11][12][13][14]. Understanding thermal phenomena and the heat transfer during the welding process is crucial for the analysis of microstructure, mechanical properties, and a quality of the weld joints [15][16][17][18].…”

Section: Introductionmentioning

confidence: 99%

Design of welding parameters for laser welding of thick-walled structures made of aluminum alloy

Babalová

Ďuriš

Behúlová

2022

J. Phys.: Conf. Ser.

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The paper deals with the laser welding of thick-walled plates with a thickness of 20 mm made of EN AW5083-H111 aluminum alloy. A simulation model for the analysis of the laser welding process is developed and verify using temperature measurement during experimental laser welding of samples by a TruDisk 4002 laser device. Based on the numerical simulation of the laser welding process in the ANSYS program code, suitable parameters for production of high-quality weld joints were suggested. For welding at a speed of 10 mm.s−1, the laser power of 7 kW is recommended. A laser with the power of 10 kW is required for the higher welding speed of 20 mm.s−1.

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Variable profile heat source models for numerical simulations of arc welding processes

Cited by 20 publications

References 34 publications

Heat source models for numerical simulation of laser welding processes – a short review

Heat source models for numerical simulation of laser welding processes – a short review

Numerical Simulation of Temperature Fields during Laser Welding–Brazing of Al/Ti Plates

Design of welding parameters for laser welding of thick-walled structures made of aluminum alloy

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