Numerical simulation of plasma arc welding with keyhole-dependent heat source and arc pressure distribution

2014 ◽  
Vol 78 (1-4) ◽  
pp. 593-602 ◽  
Author(s):  
T. Q. Li ◽  
C. S. Wu
Keyword(s):  
Numerical Simulation ◽  
Heat Source ◽  
Pressure Distribution ◽  
Arc Welding ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Arc Pressure

scholarly journals Numerical Analysis of Keyhole and Weld Pool Behaviors in Ultrasonic-Assisted Plasma Arc Welding Process

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 703
Author(s):  
Junnan Qiao ◽  
Chuansong Wu ◽  
Yongfeng Li
Keyword(s):  
Shear Stress ◽  
Weld Pool ◽  
Arc Welding ◽  
Acoustic Radiation ◽  
Radiation Force ◽  
Acoustic Radiation Force ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Arc Pressure ◽  
Ultrasonic Assisted

The acoustic radiation force driving the plasma jet and the ultrasound reflection at the plasma arc-weld pool interface are considered to modify the formulas of gas shear stress and plasma arc pressure on the anode surface in ultrasonic-assisted plasma arc welding (U-PAW). A transient model taking into account the dynamic changes of heat flux, gas shear stress, and arc pressure on the keyhole wall is developed. The keyhole and weld pool behaviors are numerically simulated to predict the heat transfer and fluid flow in the weld pool and dynamic keyhole evolution process. The model is experimentally validated. The simulation results show that the acoustic radiation force increases the plasma arc velocity, and then increases both the plasma arc pressure and the gas shear stress on the keyhole wall, so that the keyholing capability is enhanced in U-PAW.

Experimental Analysis of Welding Parameters on Variable Polarity Plasma Arc Pressure

2013 ◽  
Vol 651 ◽  
pp. 355-360 ◽  
Author(s):  
Yi Jiang ◽  
Ming Liu ◽  
Yao Hui Lu ◽  
Bin Shi Xu
Keyword(s):  
Arc Welding ◽  
Gas Flow ◽  
Welding Current ◽  
Welding Parameters ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Arc Pressure ◽  
Variable Polarity ◽  
Reversed Polarity ◽  
Variable Polarity Plasma Arc

Variable polarity plasma arc welding has been widely used to manufacture industries. The effects of welding current and plasma gas flow as the most important parameters on variable polarity plasma arc pressure were discussed experimentally. To welding current, two experimental were designed to discuss the effects of straight polarity current and reversed polarity current on arc pressure respectively. It could be concluded that arc pressure is quadratic with welding current. To plasma gas flow, both experimental and numerical analysis are used to discuss the mechanisms of plasma gas flow to arc pressure, and it could be conclude that arc pressure is quadratic with plasma gas flow rather than linear.

A DYNAMIC HEAT SOURCE MODEL WITH RESPECT TOKEYHOLE EVOLUTION IN PLASMA ARC WELDING

2013 ◽  
Vol 49 (7) ◽  
pp. 804 ◽  
Author(s):  
Yan LI ◽  
Yanhui FENG ◽  
Xinxin ZHANG ◽  
Chuansong WU
Keyword(s):  
Heat Source ◽  
Arc Welding ◽  
Source Model ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Heat Source Model

Analytical and numerical investigations of weld bead shape in plasma arc welding of thin Ti-6al-4v sheets

SIMULATION ◽  
2017 ◽  
Vol 93 (12) ◽  
pp. 1123-1138 ◽  
Author(s):  
V Dhinakaran ◽  
N Siva Shanmugam ◽  
K Sankaranarayanasamy ◽  
R Rahul
Keyword(s):  
Finite Element ◽  
Heat Source ◽  
Analytical Model ◽  
Arc Welding ◽  
Thermal Cycle ◽  
Three Dimensional ◽  
Transient Temperature ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Element Simulation

In this research work, a new analytical model has been developed to predict the temperature distribution during plasma arc welding of thin Ti-6Al-4V sheets. Dhinakaran’s model based on a three-dimensional parabolic Gaussian heat source is considered as a plasma arc heat source moving on a semi-infinite body to derive the analytical model and the same heat source model is substituted in the three-dimensional Fourier’s law of heat conduction and implemented in the finite element package. Thermo physical properties, such as density, specific heat, and thermal conductivity, are used as temperature-dependent properties in finite element simulation. Numerical simulation is carried out using COMSOL. The new analytical model is expressed as a function of three-dimensional spatial co-ordinates and the time co-ordinate. A computer program has been written to solve the analytical model in order to obtain the distribution of transient temperature at any point of interest. The transient temperature distribution predicted by the analytical model has been compared with both the experimental result and the numerical result. Experimental work is carried out to measure the thermal cycle during welding. The thermal cycle is measured by using an infrared thermometer. Very good correlation has been obtained between the predicted transient temperature by analytical solution and the measured temperature, as well as the finite element simulation result. This provides a reliable alternative for using these analytical solutions in the future to obtain the thermal cycle, distortion, and thermal stress during plasma arc welding.

Some studies on temperature field during plasma arc welding of thin titanium alloy sheets using parabolic Gaussian heat source model

2016 ◽  
Vol 231 (4) ◽  
pp. 695-711 ◽  
Author(s):  
V Dhinakaran ◽  
N Siva Shanmugam ◽  
K Sankaranarayanasamy
Keyword(s):  
Titanium Alloy ◽  
Heat Source ◽  
Arc Welding ◽  
Source Model ◽  
Bead Geometry ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Heat Source Model ◽  
Weld Bead Geometry ◽  
Source Models

In this paper, a new volumetric heat source model is developed for predicting the weld bead geometry during plasma arc welding of thin sheets of titanium alloy. Numerical simulations are carried out with the proposed parabolic Gaussian heat source (PGHS) model and already prevailing familiar heat source models namely, conical heat source and modified conical heat source, using finite element package COMSOL. The temperature-dependent material properties for Ti–6Al–4V alloy are considered for performing numerical calculations, which tend to influence the temperature fields while computing. Besides, the effect of trailing gas shielding, latent heat, and radiative and convective heat transfer are taken into account while performing the transient thermal analysis which significantly alters the sensitivity and accuracy of the model. Experimental trials on thin titanium alloy sheets are carried out to enable the validation of the proposed PGHS model. Subsequently, the outcome reveals that the PGHS model is capable and proved its high degree of efficiency in predicting the weld bead geometry more accurately than the existing heat source models. The distribution of heat intensity along the thickness of thin sheet is observed to be parabolic as predicted by the proposed model. The prediction appears to have a good correlation with the experimental result and it is clearly perceptible that the parabolic shape is more reliable and yields greater accuracy of the proposed heat source model.

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