Marangoni convection and weld shape variation in A-TIG welding process

The flux effect on TIG weld shape variations is investigated by application of the heat transfer and fluid flow model. The simulation makes use of Nimonic 263 alloy, TiO, TiO₂ and Ti₂O₃ as the flux. The arc constriction and the reversed Marangoni convection are considered to be the two main factors for increasing penetration of A-TIG weld pool. And the simulated results show that the latter is the main factor for changing weld shapes. The surface tension temperature coefficient is sensitive to the active elements and affects the pattern of the fluid flow. By controlling the category and quantity of the active elements, different kinds of the weld shapes are obtained. The experimental result shows that increase of active flux on the weld bead tends to increase the penetration of the weld pool at first and then decreases steeply. This does not coincide with the simulated results. It is probably because part of the oxide in the flux is not totally decomposed when the flux reaches a critical value. The solid oxide particles in the weld pool act as the obstacles of the fluid flow and reduce the velocity of the flow.     

SiC/AL板的焊接残余应力分析

SiC/AL功能双材料由陶瓷和金属组成,由于该材料中的SiC具有较高的抗高温能力,AL具有较高的强度,因此在航空构件中得到运用,该双材料中孔洞焊接过程中的残余应力直接影响到双材料的性能。本文采用有限元分析手段中的死活单元技术对焊接过程进行了数值模拟计算,得到了该焊接过程的残余应力分布,并与常用的钢材焊接残余应力进行对比分析。本文同时对采用弹性复变方法和积分方程分析手段得到的焊接残余应力解析解的适用性进行了阐述。     

U71Mn钢轨气压焊焊接接头滚动磨损与损伤性能研究

研究了U71Mn钢轨气压焊焊接接头上各区域的组织与性能,并利用MMS-2A轮轨滚动磨损与接触疲劳试验机对焊接接头材料进行试验,分析了各区域的磨损与损伤特性. 结果表明:焊接接头组织为珠光体,但晶粒大小及渗碳体形态和大小存在差异. 焊缝中珠光体晶粒较小,渗碳体呈细小片层状及细小颗粒状,因此硬度高且塑性变形能力强. 在1×105和2×105循环次数时耐磨性优于母材,在3×105循环次数时,焊缝磨损量大于母材磨损量,且焊缝表面损伤较母材严重. 在焊缝两侧各有1个区域(软化区),组织为粒状珠光体和少量片层状珠光体,颗粒大小和片层厚度不均匀,硬度较小,磨损量较大,塑性变形层较厚,表面损伤最严重.      

On determining the shape of weld pools

The equations governing heat and fluid flow in weld pools for the TIG fusion welding process are presented and this coupled system is solved numerically using finite differences. Electromagnetic forcing terms, buoyancy forces, shear forces on the pool surface due to the variation in surface tension with temperature and an additional uniform magnetic field applied normal to the workpiece are all included in our model and results are displayed indicating the relative importance of these four mechanisms.     

Identification of Local Viscoplastic Properties in P91 Welds from Full Field Measurements at Room Temperature and 625 °C

A methodology to obtain visco-plastic laws in heterogeneous materials with digital image correlation (DIC) is proposed based on tensile and tensile-relaxation tests conducted at room temperature and at 625 °C. Tested samples are manufactured from a P91 weld in which a microstructural heterogeneity translates into graded mechanical properties. To simplify the problem, a classical decomposition of the weld into five different domains is considered. Strain field in each domain is obtained by means of digital image correlation applied to high magnification pictures recorded with an optical long distance microscope. The conducted identifications exhibit key features in the behaviour of each domain in terms of yield stress, ultimate tensile stress and hardening at both room temperature and 625 °C. Experimental fields are compared to the fields provided by finite element simulations. Eventually, the benefit of accounting for transverse strains in the identification procedure is examined, and the robustness of the procedure with addition of noise (representative of experimental conditions) in the measurement is characterized.     

A model of the thermomechanical process during welding of plates

A model of the thermomechanical process that takes place as straight plates are welded, with due consideration of the weld seam filling, is developed within the limits of linear thermoelasticity from the temperature dependence of the properties. The filler material is assumed to be unstressed as the weld seam is filled. A modified form of constitutive equations for the filler material is proposed for implementing that assumption within the standard finite-element technique. Some laws of relative plate displacement during welding are investigated and experimental and computed results are compared. Translated from Prikladnaya Mekhanika, Vol. 34, No. 12, pp. 70–76, December, 1998.     

Comprehensive numerical analysis of a three-pass bead-in-slot weld and its critical validation using neutron and synchrotron diffraction residual stress measurements

The current paper presents a finite element simulation of the residual stress field associated with a three pass slot weld in an AISI 316LN austenitic stainless steel plate. The simulation is split into uncoupled thermal and mechanical analyses which enable a computationally less expensive solution. A dedicated welding heat source modelling tool is employed to calibrate the ellipsoidal Gaussian volumetric heat source by making use of extensive thermocouple measurements and metallographic analyses made during and after welding. The mechanical analysis employs the Lemaitre–Chaboche mixed hardening model. This captures the cyclic mechanical response which a material undergoes during the thermo-mechanical cycles imposed by the welding process. A close examination of the material behaviour at various locations in the sample during the welding process, clearly demonstrates the importance of defining the correct hardening and high temperature softening behaviour. The simulation is validated by two independent diffraction techniques. The well-established neutron diffraction technique and a very novel spiral slit X-ray synchrotron technique were used to measure the residual stress–strain field associated with the three-pass weld. The comparison between the model and the experiment reveals close agreement with no adjustable parameters and clearly validates the used modelling procedure.     

焊接接头低周疲劳裂纹扩展的统计分析与可靠性最弱环模型

在相同的试验条件下,对１６ＭｎＲ压力容器用钢焊接接头焊缝区、热影响区和母材区,分别做了１５ 根试样的低周疲劳试验,获得了三个区的低周疲劳寿命分布与裂纹扩展规律。试验表明,Ｐａｒｉｓ公式中的两个参数ｍ 和ｃ 分别服从正态分布和对数正态分布,ｍ 和ｌｏｇ ｃ 呈现统计线性关系。根据文中的统计结果,采用蒙特卡洛法对给定的两个裂纹长度间的扩展寿命进行了预测,预测结果与试验结果符合良好。文中还对焊接接头三个区的低周疲劳寿命进行了统计分析,获得了相应的概率密度函数,初步提出了整个焊接接头的可靠性最弱环模型。     

Numerical analysis of the heat and fluid flow in a weld pool with a dynamic keyhole

In keyhole plasma arc welding, the interaction between the keyhole and the weld pool occurs when the keyhole appears inside the weld pool. The change of the keyhole shape and dimensions has direct effect on the heat and fluid flow in the weld pool, and the latter will also influence the keyhole geometry. In this study, the coupled behaviors of weld pool and keyhole are treated to develop a three-dimensional model for analyzing the heat and fluid flow inside a weld pool with a dynamic keyhole. In view of the characteristics of PAW process, a combined volumetric heat source model (double-ellipsoid plus conic body source) is established, and one of its distribution parameters is adjusted dynamically with the variation of the depth of keyhole. The physical phenomena, such as the weld pool development, the keyhole formation, the evolution of fluid flow and thermal field, the full-penetration of the test plates, and the transformation from a blind keyhole to an open keyhole, are quantitatively analyzed. The numerical results reveal the regularity of fluid flow in weld pool with a keyhole. The calculated keyhole shape and the fusion zone of plasma arc welds are compared with the experimental measurements. Both agree with each other generally. It lays foundation for optimizing the welding process parameters and improving the stability of plasma arc welding process.     

Marangoni convection in weld pools with a free surface

A steady-state two-dimensional model of heat transfer and fluid flow was developed to describe Marangoni convection in the weld pool. Both the pool surface and the fusion boundary were calculated. The validity of the model was verified against an asymptotic solution for Marangoni-convection-induced free surface geometry. Two different cases were studied, i.e. a negative surface tension temperature coefficient ?γ/?T a positive one, and the resultant shapes of the weld pool surface were compared.     

Analysis of temperature and stress field in Al alloy’s twin wire welding

By analyzing the shape of twin wire welding’s arcs and the track of droplets’ transition, the phenomenon that the twin wire welding’s fore arc and rear arc all deflect to the middle of the two arcs is found. Based on this the double ellipsoid heat source model is amended, and a heat source model which can apply to calculate the twin wire welding’s temperature field is put forward. This model is testified by actual experiment of temperature sampling. By comparing the temperature field of twin wire welding and single wire welding, the results show that twin wire welding has slender weld pool the end part of which is ellipsoid, and its HAZ is narrower than that of single wire welding. So, twin wire welding can not only reduce the Al alloy generating hot crack, but can also weaken the “overaging” softened phenomenon of heat treated strengthening Al alloy. In the end, the evolving rules of 2219 Al alloy’s longitudinal and transverse stress when welded with twin wire welding are analyzed.     

A force-based failure criterion for spot weld design

This paper suggests a very simple, force-based formula that combines four failure modes into one dimensionless equation to govern spot weld failure under general static loading conditions. The four failure modes are shear, rotation, normal and peel. The normal separation mode and the peel mode are corresponding to mode I (opening mode). The tensile/shear mode is mode II (sliding mode), and the in-plane rotation mode is mode III (tearing mode). Test coupons and test fixtures are designed and tested to establish and verify this equation. To further verify this equation, a long difficult to understand automotive spot weld failure problem was studied. Applying finite element-calculated resultant loads to the proposed formula resulted in analytical values that correlated very well with the long time field observed spot weld failures. This analytical prediction reasonably explained the spot weld failure mechanism and provided good design directions to improve the durability of the auto structure.     

Metal Flow during Friction Stir Welding of 7075-T651 Aluminum Alloy

Bronze foil of 0.1 mm thickness was placed between faying surfaces of two plates to be butt-welded as marker material to reveal the flow behavior of weld metal during friction stir welding of 7075-T651 aluminum alloy. By tracing the bronze foil fragments in the weld after welding, the metal flow behavior during the welding process was revealed. Besides, the tool forces in the welding process were measured by the octagonal loop resistance turning dynamometer to expound the periodic variation of metal flow pattern. Results show that the flow behavior of the weld metal is different along the thickness direction. The flow pattern presents a periodic variation, and a formula has been proposed to calculate the periodicity of the metal flow. In addition, the weld nugget zone presents a “spoon” shape and the fine grains at the spoon handle and those at the spoon bowl are originated from different zones. A plastic metal flow model in FSW was proposed based on the results. Furthermore, the formation of defects was explained by researching the weld metal flow behavior.     

爆炸法消除焊接接头残余应力的数值模拟

利用非线性动力有限元法对爆炸处理消除焊接接头残余应力的全过程进行了数值模拟。首先，采用温度场与位移场的间接耦合方法计算了钢板对接焊的焊后冷却及残余应力的生成过程，求得焊接接头处由高温冷却到室温由于变形受到阻碍而产生的不均匀的残余塑性变形和应力。然后，在焊缝区引入移动的爆炸载荷，计算了爆炸波作用下该钢板焊接接头附近应力的变化。计算结果表明，爆炸处理可引起板内应力的重新分布，从而有效地释放超过塑性极限的残余应力。利用炸药爆炸消除大型焊接结构残余应力是一种经济有效的方法，本文的数值模拟为研究炸药爆炸消除焊接结构残余应力的机理提供了有力的工具。     

Reconstruction of the welding thermal cycle and determination of residual stresses from isotherm traces

The earlier method for reconstructing the welding thermal cycle from the dislocation of the temper colors and the cold weld joint boundaries was applied in the case of contact flash welding of rod samples. The possibility of using this method to determine the key parameters of the welding processes such as the approach speed of the welded rods, the temperature at the weld center at the beginning of cooling, and the time in which the characteristic temperature isotherm moves to the largest distance from the weld center, which allow one to reconstruct the temperature distribution curve near the weld at any time after the heating termination, was shown. The reconstructed thermal cycle was used to determine the residual stresses in the weld and in the heat-affected zone.     

确定温度分布和热应力的一种新的全息方法

本文提出了一种能获得被测模型温度场和应力场的新方法,当一个二维光弹性模型受热载荷时,用这种方法能同时在两幅全息图上记录三个信息,从而使温度场与应力场的分离成为可能。     

FUNDAMENTAL SOLUTION BASED GRADED ELEMENT MODEL FOR STEADY-STATE HEAT TRANSFER IN FGM

A novel hybrid graded element model is developed in this paper for investigating thermal behavior of functionally graded materials (FGMs). The model can handle a spatially varying material property field of FGMs. In the proposed approach, a new variational functional is first constructed for generating corresponding finite element model. Then, a graded element is formulated based on two sets of independent temperature fields. One is known as intra-element temperature field defined within the element domain; the other is the so-called frame field defined on the element boundary only. The intra-element temperature field is constructed using the linear combination of fundamental solutions, while the independent frame field is separately used as the boundary interpolation functions of the element to ensure the field continuity over the interelement boundary. Due to the properties of fundamental solutions, the domain integrals appearing in the variational functional can be converted into boundary integrals which can significantly simplify the calculation of generalized element stiffness matrix. The proposed model can simulate the graded material properties naturally due to the use of the graded element in the finite element (FE) model. Moreover, it inherits all the advantages of the hybrid Trefftz finite element method (HT-FEM) over the conventional FEM and boundary element method (BEM). Finally, several examples are presented to assess the performance of the proposed method, and the obtained numerical results show a good numerical accuracy.     

High temperature fracture parameter for a weld interface crack

A fracture parameter is introduced to characterize crack growth at elevated temperature for a weld interface crack. Finite element analyses are made for a compact tension (CT) specimen under constant load where an interface is modeled along the crack plane to simulate the dividing line of the weld metal (WM) and base metal (BM). A constitutive relation for an elastic-creeping material is used. The proposed time dependent fracture parameter is obtained for different creep constants of WM and BM. A transition time and fracture parameter for the homogeneous and welded specimens are defined such that the results can be normalized and presented in a general form for assessing the crack growth life.     

高温变形测量中热流场造成畸变的修正方法

目前高温环境中材料的变形测量是研究的热点,基于数字图像特征识别的非接触测量方法促进了高温环境变形测量的发展,但由于高温环境的复杂性,存在很多测量影响因素,其中高温环境中热流场的存在对数字图像法的影响尤为明显。本文提出了一种对高温变形测量中热流场造成畸变影响的修正方法。针对基于光学成像方法的材料高温变形测量中常见的热流场扰动,通过数值仿真得到热流场模型及热流场分布状况,再结合光线追迹原理对热流场造成的图像畸变影响进行分析,用数值分析结果对高温变形测量实验结果进行修正。对比扰动修正结果与真实位移有很好的一致性,从而证明了所提方法的可行性和有效性。     

Study on the rate-dependent cyclic deformation of super-elastic NiTi shape memory alloy based on a new crystal plasticity constitutive model

In this paper, a crystal plasticity based constitutive model (Yu et al., 2013) is extended to describe the rate-dependent cyclic deformation of super-elastic NiTi shape memory alloy by considering the internal heat production. Two sources of internal heat productions are included in the proposed model, i.e., the mechanical dissipations of inelastic deformation and the transformation latent heat in the NiTi shape memory alloy. With an assumption of uniform temperature field in the alloy specimen, a simplified evolution law of temperature field is obtained by the first law of thermodynamics and the heat boundary conditions. An explicit scale-transition rule is adopted to extend the proposed single crystal model to the polycrystalline version. The capability of the extended polycrystalline model to describe the rate-dependent cyclic deformation of super-elastic NiTi shape memory alloy is verified by comparing the predictions with the corresponding experimental ones. The comparison demonstrates that the proposed constitutive model considering the internal heat production predicts the rate-dependent cyclic deformation of super-elastic NiTi shape memory alloy fairly well.