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Arc Welding Process

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Suck-joo Na – 1st expert on this subject based on the ideXlab platform

  • Analysis of molten pool behavior by flux-wall guided metal transfer in low-current submerged Arc Welding Process
    International Journal of Heat and Mass Transfer, 2017
    Co-Authors: Degala Venkata Kiran, Suck-joo Na

    Abstract:

    Abstract A three-dimensional numerical heat transfer and fluid flow model is developed to understand the temperature distribution and molten pool behavior in a low-current submerged Arc Welding Process. The model solves the equations of the conservation of mass, momentum, and energy along with the volume of fluid method. The volume of fluid method is used to track the shape of the free surface. Further, this paper suggests a flux wall boundary model to simulate flux-wall guided transfer for a single-wire low-current submerged-Arc Welding Process. This study simulates how porosity can be trapped in the V-groove joint with a flux-wall guided transfer. The computed weld width and fusion-zone shape are in fair agreement with the corresponding experimental results.

  • Arc interaction and molten pool behavior in the three wire submerged Arc Welding Process
    International Journal of Heat and Mass Transfer, 2015
    Co-Authors: Degala Venkata Kiran, Woohyun Song, Suck-joo Na

    Abstract:

    Abstract A three-dimensional numerical heat transfer and fluid flow model is developed to understand the temperature distribution and molten pool behavior in a three wire submerged Arc Welding Process. The model solves the equations of the conservation of mass, momentum, and energy along with the volume of fluid method. The volume of fluid method is used to track the shape of the free surface. Further, a physical model is developed to estimate the Arc center displacement. For a given Welding condition, connecting the leading electrode with direct current electrode positive polarity, the middle and trailing electrodes with trapezoidal alternating current waveform displayed deeper weld pools when compared to the sine waveforms. Within the range of Welding conditions considered in the present work, weld width is significantly influenced by the leading Arc whereas the penetration by the middle and trailing Arcs. The computed weld width and penetration are in fair agreement with the corresponding experimental results.

  • molten pool behavior in the tandem submerged Arc Welding Process
    Journal of Materials Processing Technology, 2014
    Co-Authors: Daewon Cho, Degala Venkata Kiran, Woohyun Song, Suck-joo Na

    Abstract:

    Abstract A three-dimensional numerical heat transfer and fluid flow model is developed to examine the temperature profiles, velocity fields, weld pool shape and size in a two-wire tandem submerged Arc Welding Process. The model solves the equations of the conservation of mass, momentum, and energy along with the volume of fluid method. The volume of fluid method is used to track the shape of the free surface. Further, a novel scheme is proposed to handle the Arc interaction and its influence on the molten droplet transfer direction. Using the computational fluid dynamics simulations, it is found that the droplet movement and Arc forces from the leading electrode heavily affect the molten pool flow patterns and the resultant bead shapes, even though the same heat inputs are applied. The computed weld width and penetration are in fair agreement with the corresponding experimental results.

Aniruddha Ghosh – 2nd expert on this subject based on the ideXlab platform

  • Mathematical Modelling of Heat Affected Zone Width in Submerged Arc Welding Process
    2018 International Conference on Computational and Characterization Techniques in Engineering & Sciences (CCTES), 2018
    Co-Authors: Anshul Yadav, Aniruddha Ghosh, Priya Gupta, Anil Kumar

    Abstract:

    One of the most important issues faced in the submerged Arc Welding Process is the heat affected zone softening which affects the bead geometry, penetration depth and microstructure of the deposited weld metal. Therefore, the study of heat affected zone is imperative for controlling the quality of the weld. The probability of failures increases if there is a large heat affected zone which is caused by the heating and cooling cycles in the weld zone. The objective of this work is to assess the heat affected zone of welded mild steel plates through the numerical analysis and compare it with experimental results. The relation between the input parameters on heat affected zone width has also been established. The measured data of heat affected zone had excellent agreement with the predicted data from the developed model. This agreement suggests the efficacy of the developed model for predicting the HAZ characteristics in submerged Arc Welding Processes. The microstructural study of heat affected zone is also performed in this study.

  • modelling and experimental validation of moving tilted volumetric heat source in gas metal Arc Welding Process
    Journal of Materials Processing Technology, 2017
    Co-Authors: Aniruddha Ghosh, Anshul Yadav, Arvind Kumar

    Abstract:

    Abstract In this work, the effect of electrode’s tilt angle on transient temperature distribution, heat affected zone width and weld bead geometry in gas metal Arc Welding Process are investigated. Experimental, microstructure and analytical modelling studies of heat affected zone and fusion zone have been performed for different electrode tilt angles. Gaussian heat density distribution and ellipsoidal heat source shape were assumed to predict the transient temperature distribution in the welded plate. The analytical model for the transient temperature distribution in the welded plate considers heat transfers from molten droplets of the filler material, moving volumetric heat source, and convective and radiative heat losses from the welded plate. Decent agreement between the predicted and the experimental temperature distribution, heat affected zone and weld bead geometry is obtained. The comparison suggested that ellipsoidal heat source shape is quite appropriate for predicting the transient temperature distribution on the welded plate for gas metal Arc Welding Process. It was found that the heat affected zone width increases with the decrease in tilt angle. Microstructural examination on samples revealed prominent grain growth in the heat affected zone, however, fine grain structure was observed in the fusion zone. The predictions for heat affected zone width and weld bead geometry are also validated with experiments performed in shop floor Welding conditions.

  • Mathematical modeling of moving heat source shape for submerged Arc Welding Process
    The International Journal of Advanced Manufacturing Technology, 2013
    Co-Authors: Aniruddha Ghosh, Himadri Chattopadhyay

    Abstract:

    An attempt is made in this paper to find out the analytical solution of the thermal field induced in a semi-infinite body by a moving heat source with Gaussian distribution by selecting appropriate inside volume for submerged Arc Welding Process. Three different types of heat source shapes in the form of oval, double ellipsoidal, and conical forms were considered and compared with the experimental result. The study shows that for heat input of submerged Arc Welding Process, the best suitable heat source shape is in the form of an oval. The study also shows two alternate ways of predicting the size of the heat-affected zone.

C.l. Yang – 3rd expert on this subject based on the ideXlab platform

  • Numerical simulation of variable polarity vertical-up plasma Arc Welding Process
    Computational Materials Science, 2007
    Co-Authors: Hai Wang, C.l. Yang

    Abstract:

    Three-dimensional transient governing equations were developed based on conservation laws of energy, momentum and mass. These equations described physical phenomena of convection in weld pool and heat transfer in workpiece during variable polarity vertical-up plasma Arc Welding Process. Boundary conditions for the developed governing equations were given. Welding energy input for variable polarity vertical-up plasma Arc Welding Process was quantitatively expressed. Free surface deformation of the keyhole molten pool was coupled into calculation. Effect of wire filling on the geometry of molten pool and weld reinforcement was considered in the simulation. Correlations of temperature and thermophysical properties for aluminum alloy 2219 were quantitatively established. A control volume based finite difference method was used to solve the discrete governing equations. Moreover, dynamic evolutions of geometrical profile, dimension and fluid flow for the molten pool and keyhole were simulated through the developed computational routines, which achieved transient solution of fluid flow field coupling with thermophysical properties, temperature field and weld pool free surface deformation. Besides, the effect of the workpiece thickness on the moments of keyhole formation and stable keyhole establishment was analyzed, and thermal cycles for the main Welding stage were calculated. In addition, experiments via variable polarity vertical-up plasma Arc Welding technique were conducted, and the established models were experimentally verified through weld cross-section profiles.

  • Numerical simulation of variable polarity vertical-up plasma Arc Welding Process
    Computational Materials Science, 2007
    Co-Authors: H.-x. Wang, Y.-h. Wei, C.l. Yang

    Abstract:

    Three-dimensional transient governing equations were developed based on conservation laws of energy, momentum and mass. These equations described physical phenomena of convection in weld pool and heat transfer in workpiece during variable polarity vertical-up plasma Arc Welding Process. Boundary conditions for the developed governing equations were given. Welding energy input for variable polarity vertical-up plasma Arc Welding Process was quantitatively expressed. Free surface deformation of the keyhole molten pool was coupled into calculation. Effect of wire filling on the geometry of molten pool and weld reinforcement was considered in the simulation. Correlations of temperature and thermophysical properties for aluminum alloy 2219 were quantitatively established. A control volume based finite difference method was used to solve the discrete governing equations. Moreover, dynamic evolutions of geometrical profile, dimension and fluid flow for the molten pool and keyhole were simulated through the developed computational routines, which achieved transient solution of fluid flow field coupling with thermophysical properties, temperature field and weld pool free surface deformation. Besides, the effect of the workpiece thickness on the moments of keyhole formation and stable keyhole establishment was analyzed, and thermal cycles for the main Welding stage were calculated. In addition, experiments via variable polarity vertical-up plasma Arc Welding technique were conducted, and the established models were experimentally verified through weld cross-section profiles. © 2006 Elsevier B.V. All rights reserved.

  • Numerical calculation of variable polarity keyhole plasma Arc Welding Process for aluminum alloys based on finite difference method
    Computational Materials Science, 2007
    Co-Authors: H.-x. Wang, Y.-h. Wei, C.l. Yang

    Abstract:

    Variable polarity keyhole plasma Arc Welding Process was simulated via the developed models in nonorthogonal body-fitted curvilinear coordinate system depicting the physical phenomena in the keyhole weld pool. Free surface shape of the keyhole weld pool, variable polarity Welding current, temperature-dependent material thermophysical properties, wire filling, and turbulent mixing in the molten metal were considered in the computation. Transient evolution of the geometry for the keyhole weld pool was predicted. Geometrical dimensions for the keyhole molten pool at different Welding conditions were computed. Effects of wire filling, enhanced fluid thermal conductivity also kinetic viscosity on geometry and velocity field for the keyhole weld pool were analyzed. Temperature distribution for the plasma Arc was calculated. In addition, the models used were experimentally validated through the geometry of the weld cross-section. © 2006 Elsevier B.V. All rights reserved.