Numerical Simulation on Electron Beam Welding Temperature Field of Al-Li Alloy

2011 ◽  
Vol 418-420 ◽  
pp. 1640-1646
Author(s):  
Shao Gang Wang ◽  
Kuang Yu ◽  
Li Xing
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Electron Beam ◽  
Heat Source ◽  
Welding Speed ◽  
Electron Beam Welding ◽  
Beam Power ◽  
Welding Parameters ◽  
Welding Temperature ◽  
Weld Width

The numerical simulation of electron beam welding temperature field for 2090 Al-Li alloy sheet of 2 mm thickness is conducted by using the ANSYS software. The combined model of Gauss surface heat source with cylindrical body heat source in linear attenuation is used according to the unique nail-shaped weld of electron beam welding joint, and the distribution cloud image of temperature field and the instantaneous weld thermal cycle curves of Al-Li alloy electron beam welding are obtained through calculation. The effect of welding parameters such as electron beam power and welding speed on the distribution of temperature field and weld width is investigated. Results show that electron beam welding has a very high rate of both temperature ascending and descending, and the rate of temperature ascending is higher than that of descending. With the increase of electron beam power or decrease of welding speed, the temperature of fusion zone elevates, and the weld width increases. The appearance of weld obtained through numerical simulation is greatly consistent with the practical welding.

Influence of Forming Residual Stresses on the Welding Distortions of Two Thick Plates

2009 ◽  
Vol 83-86 ◽  
pp. 125-132 ◽  
Author(s):  
Sebastien Gallée ◽  
Antoine Martin ◽  
Vincent Robin ◽  
Daniel Nelias
Keyword(s):  
Numerical Simulation ◽  
Electron Beam ◽  
Heat Source ◽  
Residual Stresses ◽  
Electron Beam Welding ◽  
Initial Conditions ◽  
Rolling Process ◽  
Vacuum Vessel ◽  
Thick Plates ◽  
Simulation Results

The manufacturing of the ITER (International Thermonuclear Experimental Reactor) vacuum vessel involves the welding of thick deformed plates. The aim of this study is to investigate the influence of forming residual stresses on the welding distortions of two thick plates. The plates are deformed using a three point rolling process. A first numerical simulation is performed to investigate the residual stresses induced by this process. The forming residual stresses are taken into account as initial conditions to perform the electron beam welding simulation of a deformed plate. This simulation first requires calibrating the heat source. Two welding simulations are then performed: the first one with residual stresses and the second one without. The comparison of the simulation results points out a low effect of the residual stresses on the electron beam welding distortions. As a result, in the next electron beam welding simulations of the vacuum vessel, no forming residual stresses will be taken into account.

Numerical Simulation on Temperature Field of Electron Beam Welding of Magnesium Alloy and Study on Properties and Microstructure of Joint

2008 ◽  
Vol 575-578 ◽  
pp. 660-665 ◽  
Author(s):  
Hong Ye ◽  
Yi Luo ◽  
Zhong Lin Yan ◽  
Bin Shen
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Electron Beam ◽  
Magnesium Alloy ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Element Model ◽  
Experimental Result ◽  
Electron Beam Current ◽  
Az61 Magnesium Alloy

Magnesium alloys are being increasingly used in automotive and aerospace structures. In this study, welding of AZ61 magnesium alloy with 10 mm thickness was carried out using vacuum electron beam welding (EBW). By using the finite element model and the 3D moving double ellipsoid heat source model, numerical simulation method was employed to study the influence of the electron beam current on the temperature field of welding process and weld penetration. The microstructure and microhardness of weld joint obtained by the optimized vacuum EBW process had been investigated in detail. The results show that the numerical simulation result basically matches the experimental result. A favorable joint had been obtained by EBW for AZ61 magnesium alloy, in which heat affected zone was not evident, the fusion zone (FZ) consisted of fine-equiaxed grain. The weld hardness was greater than that of the base metal.

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

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.

scholarly journals Effect of Electron Beam Welding Parameters on Temperature and Stress Field of AISI P20 Tool Steel in Vacuum Roll-cladding Process

2021 ◽  
Author(s):  
lanyu mao ◽  
Zongan Luo ◽  
Yingying Feng ◽  
Xiaoming Zhang
Keyword(s):  
Electron Beam ◽  
Stress Field ◽  
Tool Steel ◽  
Welding Speed ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Welding Current ◽  
Temperature Fields ◽  
Welding Parameters ◽  
Aisi P20

Abstract Vacuum roll-cladding (VRC) is an effective method to produce high quality ultra-heavy AISI P20 plate steel. In the process of VRC, reasonable welding process of electron beam welding (EBW) can significantly avoid welding cracks and reduce the cost. In this paper, the electron beam welding process of AISI P20 tool steel was simulated by using a combined heat source model based on finite element method, and the temperature field and stress field under different welding parameters were studied respectively . The results showed that welding parameters have a greater effect on weld penetration than that of weld width, which making the aspect ratio increases with the increase of welding current, and decrease with the increase of welding speed. The weld morphologies were consistent with those of the modeling and the measured thermal heat curves were good agreement with those of simulated, which was verified the feasibility and effectiveness of temperature fields. The results of stress fields under different welding parameters indicat ed that lower welding speed and higher welding current resulting in lower residual stress at welded joint, which means lower risk of cracking after EBW. The results of this study have been successfully applied to industrial production.

Effects of Heat Source Model and Welding Speed on Welding Temperature Field for a Plan Carbon Steel Plant

2014 ◽  
Vol 488-489 ◽  
pp. 83-89 ◽  
Author(s):  
Z.K. Song ◽  
Z.Y. Li ◽  
J. Xu ◽  
Y.C. Sun
Keyword(s):  
Temperature Field ◽  
Carbon Steel ◽  
Heat Source ◽  
Welding Speed ◽  
Heat Input ◽  
Source Parameters ◽  
Source Model ◽  
Heat Source Model ◽  
Element Analysis ◽  
Welding Temperature

This article studies the effects of heat source shape parameter and welding speed on the evolution of welding temperature field for Q345 plan carbon steel. The heat input and heat source parameters as well as the welding speed are defined by applying DFLUX subroutine in ABAQUS to simulate the transient welding temperature. The effects of heat resource shape parameters and heat input as well as the welding speed on welding temperature field are investigated by means of finite element analysis. It has been found that heat source parameters and welding speed show strong influence on temperature distribution in FZ (fusion zone) and HAZ (heat-affected zone). Meanwhile, it shows a roughly linear relationship between the changes of heat input and the highest temperature.

scholarly journals Numerical Simulation and Experimental Investigation on Electron Beam Welding of Spray-Formed 7055 Aluminum Alloy

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1392
Author(s):  
Shaogang Wang ◽  
Zheng Wang ◽  
Chengcong Zhang ◽  
Zhiguo Wang
Keyword(s):  
Mechanical Properties ◽  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Electron Beam ◽  
Electron Beam Welding ◽  
Welded Joint ◽  
Tensile Fracture ◽  
Welding Temperature ◽  
Study Results ◽  
7055 Aluminum Alloy

The spray-formed 7055 aluminum alloy is welded by electron beam welding. Combined with the numerical simulation of a welding temperature field, the effect of different welding procedures on the microstructure and mechanical properties of welded joints is investigated in this study. Results show that the joints with good properties can be obtained under proper welding procedures. The microstructure analysis demonstrates that the fusion zone mainly consists of equiaxed grains, while a fine equiaxed grain zone is formed near the fusion line. There are mainly α(Al), MgZn2, Al2CuMg, and Mg32(Al,Zn)49 phases in the weld metal. The morphology of the weld can be improved by modification welding after the first bead welding, which is also advantageous to the mechanical properties of a welded joint. In the as-welded condition, compared with that of the base metal, the hardness of the weld zone decreased to a certain extent. The maximum tensile strength of a welded joint reaches 371.7 MPa. There are many dimples on the tensile fracture surface of a welded joint, and it dominantly presents the characteristic of ductile fracture. The simulated molten pool is consistent with the experimental weld morphology, and the reliability and accuracy of the simulation analysis are verified.

A Process Model for Electron Beam Welding with Variable Thickness

2013 ◽  
Vol 762 ◽  
pp. 538-543
Author(s):  
Jiang Lin Huang ◽  
Jean Christophe Gebelin ◽  
Richard Turner ◽  
Roger C. Reed
Keyword(s):  
Electron Beam ◽  
Variable Thickness ◽  
Process Model ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Beam Power ◽  
Welding Parameters ◽  
Eb Welding ◽  
Experimental Calibration ◽  
Beam Focusing

A process model for electron beam (EB) welding with a variable thickness weld joint has been developed. Based on theoretical aspects and experimental calibration of electron beam focusing, welding parameters including beam power, focus current, working distance and welding speed were formulated in the heat source model. The model has been applied for the simulation of assembly of components in a gas turbine engine compressor. A series of metallographic weld sections with different welding thickness were investigated to validate the predicted thermal results. The workpieces were scanned both prior to-and after welding, using automated optical metrology (GOM scanning) in order to measure the distortion induced in the welding process. The measured result was compared with predicted displacement. This work demonstrates the attempts to improve the EB welding process modelling by connecting the heat input directly from the actual welding parameters, which could potentially reduce (or even remove) the need for weld bead calibrations from experimental observation.

Effect of Welding Parameters on Temperature Field during Twin-Wire Submerged Arc Welding of X80 Pipeline Steel

2013 ◽  
Vol 652-654 ◽  
pp. 2347-2351
Author(s):  
Chun Yan Yan ◽  
Xin Zhao ◽  
Song Ya Tian ◽  
Sheng Xun Xu ◽  
Bai Qing Ma ◽  
...  
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Welding Speed ◽  
Arc Welding ◽  
Pipeline Steel ◽  
Submerged Arc Welding ◽  
Welding Parameters ◽  
X80 Pipeline Steel ◽  
Welding Temperature ◽  
Submerged Arc

The welding temperature field of twin-wire submerged arc welding (SAW) in an X80 pipeline steel welded joint was analyzed using a three-dimensional (3D) finite element (FE) model. Taking into account nonlinear relationships between temperature and mechanical properties, a coupled thermo-mechanical FE solution was used to obtain the temperature distribution for varying set of welding conditions. Effect of welding speed, inter wire spacing on welding temperature field were studied and presented. It is found that welding speed and inter wire spacing play a significant role in deciding the temperature distribution of twin-wire submerged arc welding. Simulation results were well consistent with theoretical analysis.

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