Weld process model for simulating metal active gas welding

Abstract

Generally, optimum welding variables and conditions of manufacturing are currently mainly determined by experiments for standardized production. Virtual manufacturing and virtual testing of weldments using finite element method provide a sustainable solution for advanced applications. The aim of the current research work is to develop a weld process model, using a threedimensional heat transfer model, to ensure general applicability for typical joints of stator segments of wind turbines as a final application. A systematic experimental research program, containing temperature measurements during welding, macrographs, and deformation measurements, is carried out on small-scale test specimens using different welding variables. In addition, a numerical study using uncoupled transient thermomechanical analysis is performed. The weld process model uses Goldak's double ellipsoidal heat source model for a metal active gas welding power source. It describes the correspondence between heat source parameters and net heat input for two types of electrodes. The model is validated via cross-sectional areas of fusion zones and deformations based on experiments. The relationship between current and voltage is determined based on large number of experimental data; thus, selecting a wire type, travel speed, and voltage directly defines the heat source parameters of the weld process model.

Numerical prediction and experimental validation of temperature and residual stress distributions in buried‐arc welded thick plates

“…It is concluded that the best results are obtained when η = 85%; thus, this value is taken in the numerical calculations. A similar investigation of welding process efficiency based on the comparison of numerically and experimentally obtained data are presented by Kollár et al The transient temperature field from the thermal analysis because of the heat input, with the appropriate boundary conditions, is then applied as input thermal load for the subsequent mechanical analysis. The mechanical analysis is performed simultaneously in one step, without applying the element birth and death technique to cut down simulation time .…”

Optimization‐improved thermal–mechanical simulation of welding residual stresses in welded connections

“…The thermal–mechanical simulation method acts as an effective approach to analyze the welding residual stresses (Fuina et al., 2019; Kollár et al., 2019). But the calibration of the model parameters remains a time‐consuming task, typically achieved by the trial and error method (Wang & Qian, 2022).…”