Numerical simulation of keyhole behaviors and droplet transfer in laser-MIG hybrid welding of Invar alloy

2018 ◽  
Vol 28 (9) ◽  
pp. 1974-1993 ◽  
Author(s):  
Dan Zhang ◽  
Yanhong Wei ◽  
Xiaohong Zhan ◽  
Jie Chen ◽  
Hao Li ◽  
...  
Keyword(s):  
Heat Source ◽  
Three Dimensional ◽  
Welding Process ◽  
Source Model ◽  
Experimental Results ◽  
Invar Alloy ◽  
Hybrid Welding ◽  
Droplet Transfer ◽  
Heat Source Model ◽  
Content Type

Purpose This paper aims to describe a three-dimensional mathematical and numerical model based on finite volume method to simulate the fluid dynamics in weld pool, droplet transfer and keyhole behaviors in the laser-MIG hybrid welding process of Fe36Ni Invar alloy. Design/methodology/approach Double-ellipsoidal heat source model and adaptive Gauss rotary body heat source model were used to describe electric arc and laser beam heat source, respectively. Besides, recoil pressure, electromagnetic force, Marangoni force, buoyancy as well as liquid material flow through a porous medium and the heat, mass, momentum transfer because of droplets were taken into consideration in the computational model. Findings The results of computer simulation, including temperature field in welded plate and velocity field in the fusion zone were presented in this article on the basis of the solution of mass, momentum and energy conservation equations. The correctness of elaborated models was validated by experimental results and this proposed model exhibited close correspondence with the experimental results with respect to weld geometry. Originality/value It lays foundation for understanding the physical phenomena accompanying hybrid welding and optimizing the process parameters for laser-MIG hybrid welding of Invar alloy.

Numerical simulation of flow field in the Invar alloy laser–MIG hybrid welding pool based on different heat source models

2018 ◽  
Vol 28 (4) ◽  
pp. 909-926 ◽  
Author(s):  
Xiaohong Zhan ◽  
Qi Zhang ◽  
Qibing Wang ◽  
Jie Chen ◽  
Hongbing Liu ◽  
...  
Keyword(s):  
Flow Field ◽  
Heat Source ◽  
Welding Process ◽  
Source Model ◽  
Invar Alloy ◽  
Heat Sources ◽  
Hybrid Welding ◽  
Mig Welding ◽  
Content Type ◽  
Source Models

Purpose The purpose of this paper is to establish a three-dimensional flow field model of the Invar alloy laser–metal inert gas (laser–MIG) hybrid welding process to investigate the influence of different heat sources between different layers and to analyze the flow field based on the two different heat source models for the multilayer welding. Design/methodology/approach The Invar steel plates with 19.5 mm thickness are welded into three layers’ seam using the hybrid laser–MIG welding technology. The flow field based on different heat source models is studied and then used to investigate the influence of different heat sources in different layers during the laser–MIG hybrid welding process. The simulation results of flow field using two different heat source models are compared with experiments. Findings The flow field simulations results show that using the Gaussian rotating body heat source model to simulate the temperature field is more consistent with the experiment of the hybrid laser–MIG welding where its flow field between different layers better reflects the characteristics of the hybrid laser–MIG welding. Originality/value The findings will be useful in the study of a variety of thick-plate laser–MIG hybrid welding process fluid flows.

The New Heat Source Model of AZ31B Magnesium Alloy Laser-TIG Hybrid Welding

2019 ◽  
Vol 815 ◽  
pp. 120-124 ◽  
Author(s):  
Zhong Lin Hou ◽  
Tan Zhao ◽  
Zhen Xu ◽  
Long Hao Zhu ◽  
Jian Hua Sun ◽  
...  
Keyword(s):  
Magnesium Alloy ◽  
Heat Source ◽  
Weld Pool ◽  
Inflection Point ◽  
Source Model ◽  
Hybrid Welding ◽  
Single Source ◽  
Heat Source Model ◽  
Keyhole Effect ◽  
Body Heat

A new heat source model consisted of inverted conical heat source and rotary Gauss body heat source is established using the CAE software for the keyhole effect of laser-TIG hybrid welding. The inverted conical heat source is used for analyzing the wide upper part of weld pool due to the rapid heat up by the laser and arc. The rotary Gauss body heat source model is used for analyzing the long and narrow lower part of weld pool formed by the laser. The result showed that, compared with other single source mode, this new heat source model may get a better simulation of the weld pool morphology, especially the inflection point near the keyhole. It provides a new method to predict the morphology and size of the weld pool of magnesium alloy laser-TIG welding.

Heat Source Model of Lap Laser Welding of Stainless Steel Vehicle

2011 ◽  
Vol 121-126 ◽  
pp. 3347-3351 ◽  
Author(s):  
Hong Xiao Wang ◽  
Chun Sheng Wang ◽  
Chun Yuan Shi ◽  
Zhi Yi Huang
Keyword(s):  
Stainless Steel ◽  
Heat Source ◽  
Laser Welding ◽  
Process Parameters ◽  
Production Efficiency ◽  
Three Dimensional ◽  
Source Model ◽  
Heat Source Model ◽  
Element Analysis ◽  
Welding Temperature

Resistance spot welding (RSW) is being taken place by partial lap laser welding for the poor surface quality and bad airtight due to the pressure of electrodes. The shape of partial lap laser welding is similar to the vase. When the penetration of the joint is in a certain range, there is no welding trace on the outer surface. Laser welding temperature field numerical analysis based on Abaqus finite element analysis software is committed to obtain a suitable range of process parameters to improve production efficiency and automation by determining the joint penetration. To master the laser lap welding of stainless steel weld penetration state, the combination of three-dimensional positive cone + three-dimensional inverted cone + half-ellipsoid heat source model was established simulating stainless steel lap laser weld pool shape and forecasting the range of process parameters .

Temperature Simulation of Aluminium Alloy Double-Arc Welding Process on Simplified Conditions

2013 ◽  
Vol 661 ◽  
pp. 158-161
Author(s):  
Guo Hong Ma ◽  
Zhao Yang Zhang ◽  
Jia Ye
Keyword(s):  
Temperature Field ◽  
Heat Source ◽  
Arc Welding ◽  
Welding Process ◽  
Source Model ◽  
Heat Source Model ◽  
Finite Element Software ◽  
Single Arc ◽  
Forming Characteristics ◽  
Arc Welding Process

In this paper we used ANSYS finite element software to simulate the temperature field in 7a52 aluminum alloy double-arc welding process and analyze the welding seam's forming characteristics. We conducted the welding temperature field numerical simulation in the same welding seam forming conditions by loading heat source of single-arc and double-arc separately, which used gauss heat source model and used voltage, welding current and speed as key parameters. The experiments indicated that the designed double-arc heat source model could generally represent the double-arc welding process. Compared with single-arc welding process, the double-arc welding had higher welding efficiency and narrower heat affected zone. Furthermore, the temperature of double-arc welding pool raised faster. All these advantages could improve the welding efficiency.

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