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.     

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.     

Coupled heat transfer and viscous flow,and magnetic effects in weld pool analysis

A finite element formulation and analysis is developed to study coupled heat transfer and viscous flow in a weld pool. The thermal effects generate not only buoyancy forces but also a variation in the surface tension which acts to drive the viscous flow in the molten weld pool. A moving phase boundary separates molten and solid material. Numerical experiments reveal the nature of the highly convective flow in the weld pool and the associated thermal profiles. The relative importance of buoyancy, surface tension, phase change, convection, etc. are examined. We also consider the sensitivity of the solution to the finite element mesh and related non-linear numerical instabilities. Of particular interest is the coupling of the thermal and viscous flow fields for the case when radial flow is inward or outward.     

Modeling of the thermal fluid flow and keyhole shape in stationary plasma arc welding

A three dimensional transient model has been developed to investigate the fluid flow and heat transfer in the weld pool with a dynamic-variation keyhole during stationary plasma arc welding (PAW). The level set method is used to track the moving boundary of the keyhole, and the evolution of both keyhole and weld pool in stationary keyhole PAW process are quantitatively analyzed. The thermal fluid flow of the molten metal surrounding the keyhole inside the weld pool is numerically simulated, and its effect on the keyhole shape is considered. The establishing time of an open keyhole is calculated for the stationary plasma arc welding of stainless steel plates with thickness 6 mm. The stationary keyhole PAW experiments are conducted to measure the keyhole shape, the fusion zone, and the establishment time of the keyhole. The predicted results, such as the keyhole length and width at bottom-side, the weld width at top- and bottom-side, and the establishment time of the keyhole, are in agreement with the experimental measurement.     

Three dimensional modeling weld solidification cracks in multipass welding

This paper utilizes element birth and death finite element technique to control the process of filling metal step by step during multipass welding process. The dynamic thermal distributions and strain evolutions are simulated in 10 mm SUS310 stainless steel in multipass welding after taking into consideration of the fluid flow in the weld pool, the latent heat, taking into account the effect of the deformation in weld pool, change of initial temperature and solidification shrinkage. At the same time, the driving forces to weld solidification cracks of each weld pass are obtained successfully according to simulated thermal cycle (temperature against time) and mechanical strain cycle (mechanical strain against time). The results show the patterns of distribution of the driving force are similar to those of surface fusion welding. The driving force of first weld pass is larger than following weld passes and the driving force decreases gradually in company with welding processing. Sequent welding processes affect the mechanical strain distributions of previous weld pass, of which the tensile mechanical strain changes to compressive strain. In addition, the driving forces are analyzed and weld solidification cracks are predicted during multipass welding. The predicted results agree well with the experiments. Therefore, the simulated results in this study provide the foundation for predicting weld solidification cracking in actual weldment.     

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.     

Pool boiling heat transfer of deionized and degassed water in vertical/horizontal V-shaped geometries

Nucleate pool boiling using a surface within an angular geometry was conducted in saturated, deionized and degassed water. Data were taken at atmospherical pressure and at heat fluxes from 300 W/m ² to 51000 W/m ² while decreasing the heat flux. The effects of the angle on the initiation of boiling of nearly contact line are documented, and a model for pool boiling heat transfer in vertical/horizontal V-shaped geometries was correlated in the form of equation (4). It was also found that the angular geometry was presented to have a distinct advantage in boiling heat transfer coefficient relative to the flat plate. In addition, the pool boiling heat transfer of the vertical/horizontal V-shaped geometries were shown the same tendency, but, the results on the same conditions also showed that the enhancement ratios of the vertical V-shaped geometries are averagingly higher than those of the horizontal V-shaped geometries. In general, the results reveal the importance of the angular geometry to the enhanced nucleate boiling heat transfer of structured surface, and it is also attributed to information for the development of more effective surfaces. The financial support extended by the National Science Council of the Republic of China through grant No. NSC-90-2212-E-230-002.     

Frequency related localisation of harmonic elastic waves in stratified welds

The paper presents a computational model for elastic waves in a structured weld adjacent to the free surface of an elastic solid. The main emphasis is on the interaction of waves with the micro-structure of the weld. Effects of localisation and channeling of waves are addressed. A model of a grain structure within the weld is also considered.     

两种热处理钢轨焊接接头冲击磨损与损伤性能研究

研究了过共析钢轨焊接接头淬火和正火后不同区域的硬度与微观组织,利用冲击磨损试验机对不同区域进行冲击试验,分析了各区域冲击磨损与损伤特性. 结果表明:钢轨焊接接头分为母材区、焊缝区和热影响区. 母材区微观组织为片层状珠光体,焊缝区为珠光体与先共析铁素体且正火后铁素体含量较多,热影响区淬火后为粒状珠光体而正火后存在少量片层状珠光体. 焊接接头不同区域硬度大小为母材区>淬火焊缝区>正火焊缝区>正火热影响区>淬火热影响区. 硬度越低的区域,冲击深度和磨损体积越大. 母材区冲击损伤轻微,表面呈轻微剥落;焊缝区损伤较严重,出现明显裂纹且正火后损伤较淬火后严重;热影响区损伤最为严重且正火后损伤较淬火后略轻微.      

Identification of Heterogeneous Constitutive Parameters in a Welded Specimen: Uniform Stress and Virtual Fields Methods for Material Property Estimation

Local strain data obtained throughout the entire weld region encompassing both the weld nugget and heat affected zones (HAZs) are processed using two methodologies, uniform stress and virtual fields, to estimate specific heterogeneous material properties throughout the weld zone. Results indicate that (a) the heterogeneous stress–strain behavior obtained by using a relatively simple virtual fields model offers a theoretically sound approach for modeling stress–strain behavior in heterogeneous materials, (b) the local stress–strain results obtained using both a uniform stress assumption and a simplified uniaxial virtual fields model are in good agreement for strains ɛ _xx < 0.025, (c) the weld nugget region has a higher hardening coefficient, higher initial yield stress and a higher hardening exponent, consistent with the fact that the steel weld is overmatched and (d) for ɛ _xx > 0.025, strain localization occurs in the HAZ region of the specimen, resulting in necking and structural effects that complicate the extraction of local stress strain behavior using either of the relatively simple models.

Investigation of droplets impinging on a deep pool: transition from coalescence to jetting

An experimental investigation of droplets impinging vertically on a deep liquid pool of the same fluid was conducted. Coalescence and jetting as two of the main regimes were identified and studied. Five fluids, distilled water, technical ethanol, n-pentane, methanol and 1-propanol were used for providing different liquid-phase physical properties with density from 600 to 1,000 kg/m³, viscosity from 0.20 to 2.00 mPa s, and surface tension from 13.7 to 72.0 mN/m. Except for the experimental run of n-pentane, which was carried out in n-pentane saturated vapor, the ambient gas for the other experiments was air. The impact processes of micro-level (diameter below 1 mm) droplets were captured using a high-speed camera with a backlight. The observations, velocity and diameter ranges of the experimental runs were described, and based on them, the effects of the liquid-phase properties were studied. It was found that both low viscosity and low surface tension can increase the instability during impact processes. By curve-fitting, the transition from coalescence to jetting was characterized by using two models, one employing the Weber number (We) and the Ohnesorge number (Oh), and one employing the Froude number (Fr) and the Capillary number (Ca). Both models characterize the coalescence-jetting threshold well. The We-Oh model was based on a commonly used model from Cossali et al. (in Exp Fluids 22:463–472, 1997) for characterizing coalescence-splashing. For the small droplet diameters (below 1 mm) considered in this study, it was required to modify the We-Oh model with a diameter-dependent term to fit the sharp change in thresholds for fluids with relatively high viscosity. The Fr-Ca model has not previously been presented in the literature. A comparison of the two models with literature data (Rodriguez and Mesler, J Colloid Interface Sci 106(2):347–352, 1985) indicates that they are also valid for impacts of droplets with diameters above 1mm. Calculation methods to generalize the two models were proposed.     

U71MnK钢轨焊缝滚动接触磨损性能研究

对U71Mn K钢轨焊缝及母材在滚动接触疲劳条件下进行模拟试验,对比研究了钢轨焊缝及母材在滚动接触过程中的材料磨损演变行为.结果表明:以U71Mn K为基材的钢轨焊缝部位与非焊缝部位的磨损性能及组织结构在磨损前后均存在显著差异.由于组织结构和力学性能的差异,焊缝区硬度低于非焊缝区,焊缝区摩擦系数、磨损量、磨损率均大于非焊缝区.与非焊缝区相比,钢轨焊缝区容易产生犁沟乃至波磨,表面粗糙度增大,剥落损伤、裂纹、塑性变形严重,磨损性能变坏.无论焊缝区还是非焊缝区,其先前的磨损细化了组织,改善了其磨损性能,减弱了其后的摩擦损伤.     

Experimental studies on CHF characteristics of nano-fluids at pool boiling

To investigate the CHF characteristics of nano-fluids, pool boiling experiments of nano-fluids with various concentrations of TiO₂ or Al₂O₃ nanoparticles were carried out using a 0.2 mm diameter cylindrical Ni–Cr wire under atmospheric pressure. The results show that the CHFs of various nano-fluids are significantly enhanced over that of pure water. SEM observation subsequent to the CHF experiment revealed that a nanoparticle coating is generated on the wire surface during pool boiling of nano-fluids. The CHF of pure water was measured on a nanoparticle-coated wire which was produced during the pool boiling experiments of nano-fluids. The CHF of pure water on the nanoparticle-coated wire was similar to that of nano-fluids. This result clearly shows that the main reason for CHF enhancement of nano-fluids is the modification of the heating surface by the nanoparticle deposition. The nanoparticle-coated surface was characterized with various parameters closely related to pool boiling CHF: surface roughness, contact angle, and capillary wicking performance. Finally, CHF enhancement of nano-fluids is discussed using the parameters.     

氧乙炔焰喷焊挺杆抗点蚀性能的试验研究

作者以45号钢为基材,对其施行表面喷焊覆层强化处理的工艺,试验研究了氧乙炔焰喷焊斯太尔挺杆与国产斯太尔凸轮配副的抗点蚀性能。结果表明,在相同工况下,氧乙炔焰喷焊挺杆的优点蚀寿命比212堆焊合金铸铁挺杆的长一倍,比按国外原图纸工艺要求试制的20Cr气体软氮化斯太尔挺杆的长4培。文章还就喷焊挺杆的点蚀失效机理、挺杆表面喷焊覆层的抗点蚀性能和喷焊工艺对挺杆抗点蚀性能的影响等进行了比较系统而深入的分析和讨论,指出这种喷焊上艺可以应用于斯太尔挺杆的国产化批量生产。     

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。     

Flow analysis of the weld line formation during injection mold filling of thermoplastics

To study the weld line formation of colliding flow fronts the filling of a mold cavity was simulated. The thermo-rheological findings were used to investigate the sources of weld line weakness. In this way critical areas of the interface in regard to the lack of interdiffusion and the inappropriate molecular orientation were found to be placed near the surface of the finished parts. The main source for the weld line weakness seems to be the V-notch that arises due to the poorly bonded region near the surface in combination with the large shrinkage as a result of extremely high molecular orientations induced at the end of the filling. Furthermore, the empirical knowledge was confirmed that weld lines are rather more sensitive to the local flow situation than the global processing conditions. Melt and mold temperatures can be considered to be the most important factors which influence the weld line strength.In part presented at the 6th European Conference on Rheology, Erlangen, 2002     

Simulation of temperature fields in arc and beam welding

 Heat and mass transfer in arc and beam welding is considered. The main objectives are analysis of the heat transfer in the weld pool and the workpiece and to demonstrate how computer simulation can be used as a tool to predict the temperature distribution as the determining element of the heat effects of welding. Simulation results of two particular welding processes are compared and validated with measurements. Received on 26 July 1999     

Simulation and experimental analysis of melt pool evolution in laser engineered net shaping

In this work, the evolution of melt pool under single-point and single-line printing in the laser engineered net shaping (LENS) process is analyzed. Firstly, the basic structure of the melt pool model of the LENS process is established and the necessary assumptions are made. Then, the establishment process of the multi-physical field model of the melt pool is introduced in detail. It is concluded that the simulation model results are highly consistent with the online measurement experiment results in terms of melt pool profile, space temperature gradient, and time temperature gradient. Meanwhile, some parameters, such as the 3D morphology and surface fluid field of the melt pool, which are not obtained in the online measurement experiment, are analyzed. Finally, the influence of changing the scanning speed on the profile, peak temperature, and temperature gradient of the single-line melt pool is also analyzed, and the following conclusions are obtained: With the increase in scanning speed, the profile of the melt pool gradually becomes slender; The relationship between peak temperature and scanning speed is approximately linear in a certain speed range; The space temperature gradient at the tail of the melt pool under different scanning speeds hardly changes with the scanning speed, and the time temperature gradient at the tail of the melt pool is in direct proportion to the scanning speed.     

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.     

Fatigue crack growth studies in rail steels and associated weld metal

Fatigue crack growth studies in rail steels and associated weld metal have shown that (a) deformed rail steel exhibited fatigue crack growth rates that are slightly faster than undeformed rail steel and (b) weld metal growth data are appreciably faster than rail steel growth results and exhibit growth rate plateaux that reside above the upper bound reported for rail steel fatigue crack growth.In rail steel microstructures at low ΔK levels fatigue crack extension occurred by a ductile striated growth mechanism. However at K_max values approaching 40 MPa √m transgranular cleavage facets initially formed and their incidence increased with K_max until final fast fracture. The average cleavage facet size agreed well with pearlite nodule dimensions of 60–100 μm.The weld metal microstructure was much coarser than the rail steel and contained highly directional columnar grain growth. At all ΔK levels the dominant fracture mode was transgranular cleavage containing small isolated regions of ductile striated fatigue crack growth. The cleavage facet size varied from 150 to 600 μm; such a large variation was explained by the fact that in general crack extension tended to occur in association with the proeutectoid ferrite phase.