Part I: Development of new heat source model applicable to micro electron beam welding

Abstract An adapted heat source model is developed for transient thermal numerical analysis of electron beam welded nickel-based alloy with increased susceptibility to hot cracking. The model enables the consideration of heat redistribution due to beam deflection phenomena. The modeling concept is validated by the appropriate theoretical models and in addition, experimental studies especially performed for this purpose. Special attention is given to the calibration of heat source model parameters. The calibration procedure is based on a statistical approach involving a combination of novel analytical solutions and quasi-steady state finite element models. The model parameter field is statistically analyzed, and a prediction algorithm is developed using optimization algorithms from the six sigma theory. The reliability and practicability of the model is demonstrated by validation weldments. The work is dedicated to precisely calculating the temperature field in the high temperature region around the weld pool and thus to provide a more detailed explanation of the formation of hot cracks when welding turbine materials commonly used in industry and aircraft constructions.

Download Full-text

ESTABLISHMENT OF SEGMENTED MOVING DOUBLE ELLIPSOID HEAT SOURCE MODEL IN ELECTRON BEAM WELDING NUMERICAL SIMULATION

Journal of Mechanical Engineering ◽

10.3901/jme.2004.02.165 ◽

2004 ◽

Vol 40 (02) ◽

pp. 165 ◽

Cited By ~ 4

Author(s):

Yu Wang

Keyword(s):

Numerical Simulation ◽

Electron Beam ◽

Heat Source ◽

Electron Beam Welding ◽

Source Model ◽

Heat Source Model

Download Full-text

Multiscale modeling of electron beam and substrate interaction: a new heat source model

Computational Mechanics ◽

10.1007/s00466-015-1170-1 ◽

2015 ◽

Vol 56 (2) ◽

pp. 265-276 ◽

Cited By ~ 38

Author(s):

Wentao Yan ◽

Jacob Smith ◽

Wenjun Ge ◽

Feng Lin ◽

Wing Kam Liu

Keyword(s):

Electron Beam ◽

Heat Source ◽

Multiscale Modeling ◽

Source Model ◽

Heat Source Model ◽

Substrate Interaction

Download Full-text

Modeling of the Temperature Field during Electron Beam Welding of Aluminum Alloy by a Pre-Defined Keyhole

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.353-358.2011 ◽

2007 ◽

Vol 353-358 ◽

pp. 2011-2014

Author(s):

Yan Hong Tian ◽

Chun Qing Wang ◽

Dan Yang Zhu

Keyword(s):

Temperature Field ◽

Electron Beam ◽

Heat Source ◽

Electron Beam Welding ◽

Three Dimensional ◽

Source Model ◽

Transient Temperature ◽

Al Alloy ◽

Welding Pool ◽

Welding Line

The transient temperature field of Al alloy during electron beam welding (EBW) process was simulated using a three-dimensional finite element method. Different from the most previous models which were based on the assumption that the welding pool was solid and neglected the existence of keyhole by meshing the solid as a whole, a dynamic three-dimensional keyhole was applied in this model. The profile of the keyhole was ellipse and its size was determined before simulation based on the results of experiments. Following the heat source, the pre-defined keyhole moved along the welding line. A three-dimensional complex heat source model, including a modified Gaussian distribution source and a uniform source, was used in this study. The result shows that the shape of the keyhole had a direct effect on the temperature distribution and contribution to the special shape of the welding pool in EBW.

Download Full-text