A Macro-Micro Model of Fusion Zone Microstructure Evolution in Mn-C Low-Alloy Steel Coupled With Thermal Stress Analysis

A macro-micro-model for microstructure evolution in the fusion zone of a l.2 Mn and 0.11 C low-alloy steel is described. The macro-model is a 3D transient thermal analysis of a welded structure that resolves the weld pool with element size greater than 1 mm and time steps greater than 1 second. The micro-model has cell size of about 1 micron and time step size of about 10 micro-seconds with a grid of about 80×80×500 cells. The micro model is positioned on the liquid-solid interface of the weld pool in the macro-model. The boundary conditions for the micro-model are mapped from the macro-model. The micro-model solves the 3D transient solute diffusion equations for Mn and C. The micro-model computes the liquid-solid interface movement with local velocities determined by local temperature, compositions of solid and liquid phases and interface curvature to predict columnar or dendritic solidification structures. As the solid cools from the melting point to room temperature, the evolution of austenite, ferrite, pearlite, bainite and martensite phases are computed. The 3D transient stress due to temperature and phase changes is computed in the micro-model as it cools from the melting temperature to room temperature. At room temperature a micro-model tensile test is run to 4% strain. The macro-stress and strain is compared to the micro-stress and strain distributions. The model is intended to be used to initialize models of fracture, fatigue and creep in weld fusion zones.