☆ 4.7 Article

Development of egg-configuration heat source model in numerical simulation of autogenous fusion welding process

INTERNATIONAL JOURNAL OF THERMAL SCIENCES (2014)

Journal

INTERNATIONAL JOURNAL OF THERMAL SCIENCES

Volume 86, Issue -, Pages 125-138

Publisher

ELSEVIER FRANCE-EDITIONS SCIENTIFIQUES MEDICALES ELSEVIER

DOI: 10.1016/j.ijthermalsci.2014.06.032

Keywords

Finite element method; Volumetric heat source; Numerical model; Laser welding; GTA welding

Funding

Indian Institute of Technology Guwahati, Guwahati, Assam, India [SG/ME/P/SB/1]

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Abstract

The mathematical structure of the heat source models should at least approximately represent the phenomena of real heat source. In fusion welding process, only the surface heat flux fails to realize enhanced heat transfer due to predominant effect of momentum transport of the material within molten pool. The convection in the weld pool can be substituted by apparent volumetric heat source which is unrealistic to define outside the molten pool volume. The key issues to define a decent volumetric heat source are the geometric shape and size, non-symmetric heat density distribution due to moving arc or laser beam. In present work, the egg-configuration volumetric heat source model is proposed to address these issues. The proposed heat source model which is derived from ellipsoid shape provides the non-symmetry heat energy distribution with less number of model parameters and conserves the continuity in profile during moving heat source problem. The general equation of egg-configuration heat source provides the basis of Gaussian distributed disc, hemispherical, and semi-ellipsoidal volumetric heat source models which can be considered as the special cases of proposed heat source model. A 3D finite element based transient heat transfer analyses is conducted using the proposed heat source model for gas tungsten arc welding (GTAW) and diode laser welding processes. The maximum deviation of 10% in weld pool size estimation is observed as compared to experimental results. The time-temperature history confirms the peak temperatures of 940 IC and 1060 K, respectively for GTAW and laser welding processes. The amount of the maximum cooling rate predicted for GTAW is 603 K/s which is significantly lower than 11.1 x 10(3) K/s for laser welding. Overall, the proposed heat source model generalized the applicability over a wide variety of materials and autogenous fusion welding processes. (C) 2014 Elsevier Masson SAS. All rights reserved.

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Thermal finite element modeling of the laser beam welding of tailor welded blanks through an equivalent volumetric heat source

Vito Busto, Donato Coviello, Andrea Lombardi, Mariarosaria De Vito, Donato Sorgente

Summary: In the past few decades, various numerical models have been developed to simulate the keyhole laser welding process, including sophisticated multiphase models and less computationally expensive thermo-mechanical models. This study used a double-conical volumetric heat source to evaluate the laser joining process of sheets with different thicknesses, and the experiments showed that the model could satisfactorily estimate the shape and dimensions of the fused zone.

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