A three dimensional model with a moving heat source is developed to describe heat transfer and fluid flow in transient weld pools. Full penetration and free top and bottom surfaces are incorporated in the model in order to simulate the welding process more practically. The influence of plate thickness and welding current on the dynamics of weld pools is analyzed using calculated data. It is shown that when the workpiece is nearly penetrated, the depth of weld pool increases quickly. Also, the elevation of the top surface decreases quickly once the full penetration status is established.
Issue Section:
Research Papers
1.
Attey
D. R.
1980
, “A Mathematical Model for Fluid Flow in a Weld Pool at High Current
,” Journal of Fluid Mechanics
, Vol. 98
, p. 787
787
.2.
Oper
G. M.
Szekely
J.
1984
, “Heat and Fluid Flow Phenomena in Weld Pools
,” Journal of Fluid Mechanics
, Vol. 147
, p. 53
53
.3.
Kou
S.
Wang
Y. H.
1986
, “Computer Simulation of Convection in Moving Arc Weld Pools
,” Metall. Trans.
, Vol. 17A
, p. 2271
2271
.4.
Tsao
K. C.
Wu
C. S.
1988
, “Fluid Flow and Heat Transfer in GTA Weld Pools
,” Weld. J.
, Vol. 67
, 1988, p. 70s
70s
.5.
Kim
S. D.
Na
S. J.
1989
, “A Study of Heat and Mass Flow in Stationary Gas Tungsten Arc Welding Using the Numerical Mapping Method
,” Proc. Instn. Mech. Engrs. Part B Journal of Engineering Manufacture
, Vol. 203
, p. 233
233
.6.
Thompson
M. E.
Szekely
J.
1989
, “The Transient Behavior of Weld Pools With a Deformed Free Surface
,” Inter. J. of Heat and Mass Transfer
, Vol. 32
, p. 1007
1007
.7.
Choo
R. T. C.
Szekely
J.
1990
, “Modeling of High-Current Arc With Emphases on Free Surface Phenomena in the Weld Pool
,” Weld. J.
, Vol. 69
, p. 223s
223s
.8.
Tsai
M. C.
Kou
S.
1989
, “Marangoni Convection in Weld Pools With a Free Surface
,” Inter. J. of Numerical Methods in Fluid
, Vol. 9
, p. 1503
1503
.9.
Kim
S.-D.
Na
S.-J.
1994
, “A Study on the Three-Dimensional Analysis of Heat and Fluid Flow in Gas Metal Arc Welding Using Boundary-Fitted Coordinates
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol. 116
, p. 78
78
.10.
Kim
S.-D.
Na
S.-J.
1992
, “Effect of Weld Pool Deformation on Weld Penetration in Stationary Gas Tungsten Arc Welding
,” Weld. J.
, Vol. 71
, p. 179s
179s
.11.
Zacharia
T.
1989
, “Three-Dimensional Transient Model for Arc Welding Process
,” Metall. Trans.
, Vol. 20B
, p. 645
645
.12.
Zacharia
T.
1989
, “Modeling of Non-Autogenous Welding
,” Weld. J.
, Vol. 68
, p. 18s
18s
.13.
Sheng
I. C.
Chen
Y.
1992
, “Modeling Welding by Surface Heating
,” ASME Journal of Engineering Materials and Technology
, Vol. 114
, p. 439
439
.14.
Chen
Y.
Sheng
I. C.
1993
, “On the Solid-Liquid Transition Zone in Welding Analysis
,” ASME Journal of Engineering Materials and Technology
, Vol. 115
, p. 17
17
.15.
Kou
S.
Wang
Y. H.
1986
, “Computer Simulation of Convection Moving Arc Weld Pools
,” Metal Trans.
, Vol. 17A
, p. 2271
2271
.16.
Zacharia
T.
1995
, “Surface Temperature Distribution of GTA Weld Pools on Thin-Plate 304 Stainless Steel
,” Weld. J.
, Vol. 74
, p. 353s
353s
.17.
Kovacevic
R.
Zhang
Y. M.
Ruan
S.
1995
, “Sensing and Control of Weld Pool Geometry for Automated GTA Welding
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol. 117
, p. 210
210
.18.
Kovacevic
R.
Zhang
Y. M.
Li
Lin
Monitoring of Weld Penetration Based on Weld Pool Appearance
,” Welding Journal
, Vol. 75
, 1996
, p. 317s
317s
.19.
Zhang
Y. M.
1993
, “Determining Joint Penetration in GTAW With Vision Sensing of Weld-Face Geometry
,” Weld. J.
, Vol. 72
, p. 463s
463s
.20.
Zhang
Y. M.
Kovacevic
R.
Wu
L.
1996
, “Dynamic Analysis and Identification of Gas Tungsten Arc Welding Process for Full Penetration Control
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol. 118
, No. 1
, p. 123
123
.21.
Kovacevic, R., Zhang, Y. M., and Ruan, S., 1993, “Three-Dimensional Measurement of Weld Pool Surface,” Proceedings of the International Conference on Modeling and Control of Joining Processes, p. 607, Orlando, Florida, Dec. 8–10, ASM.
22.
Zhang
Y.
Beardsley
M.
Kovacevic
R.
1994
, “Real-time Image Processing in 3D Measurement of Weld Pool Surface
,” Manufacturing Science and Engineering, PED-Vol. 68-1, p. 255, ASME. Also in ASME JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING
, Vol. 119
, No. 2
, p. 161
161
.23.
Choi
M.
Greif
R.
1987
, “A Study of the Heat Transfer During Arc Welding With Applications to Pure Metals Temperature Materials
,” Numerical Heat Transfer
, Vol. 11
, p. 477
477
.24.
Ohji, T., and Nishiguchi, K., 1983, “Mathematical Modeling of Molten Pool in Arc Welding of Thin Plate,” IIW DOC.211-555-83.
25.
Zhang
Y. M.
Li
L.
Kovacevic
R.
1995
, “Dynamic Correlation Between Weld Pool Shape and Weld Penetration
,” ASME International Mechanical Engineering Congress, MD Vol. 69-2, p. 883, 12–17, November, San Francisco, CA. Also in ASME JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING
, Vol. 119
, No. 4
, p. 631
631
.26.
Lin
M. L.
Eagar
T. W.
1986
, “Pressure Produced by Gas Tungsten Arcs
,” Metal Trans.
, Vol. 17B
, p. 601
601
.27.
Patankar, S. V., 1980, Numerical Heat Transfer and Fluid Flow, McGraw-Hill.
28.
Kovacevic, R., and Zhang, Y. M., 1995, “Vision Sensing of 3D Weld Pool Surface,” The 4th International Conference on Trends in Welding Research,5–8 June, Gatlingburg, TN.
29.
Burgardt
P.
Hiple
C. R.
1992
, “Weld Penetration Sensitivity to Welding Variable When Near Full Joint Penetration
,” Weld. J.
, Vol. 71
, p. 341s
341s
.
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