Elucidation of the weld pool convection and keyhole formation mechanism in the keyhole plasma arc welding

Heat and fluid flow in low-Prandtl number melt pools (Pr = O(10 −1)) during laser processing of materials are sensitive to the prescribed boundary conditions, and the responses are highly nonlinear. Previous studies have shown that fluid flow in melt pools with surfactants can be unstable at high Marangoni numbers. In numerical simulations of molten metal flow in melt pools, surface deformation and its influence on the energy absorbed by the material are often neglected. However, this simplifying assumption may reduce the level of accuracy of numerical predictions with surface deformations. In the present study, we carry out three-dimensional numerical simulations to realise the effects of surface deformations on thermocapillary flow instabilities in laser melting of a metallic alloy with surfactants. Our computational model is based on the finite-volume method and utilises the volumeof-fluid (VOF) method for gas-metal interface tracking. Additionally, we employ a dynamically adjusted heat source model and discuss its influence on numerical predictions of the melt pool behaviour. Our results demonstrate that including free surface deformations in numerical simulations enhances the predicted flow instabilities and, thus, the predicted solid-liquid interface morphologies.

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“…where, λ is an adjustment factor to conserve the total heat input [21] at every time-step, and is defined as follows:…”

Section: Governing Equations and Boundary Conditionsmentioning

confidence: 99%

The Influence of Surface Deformation on Thermocapillary Flow Instabilities in Low Prandtl Melting Pools with Surfactants

Ebrahimi¹,

Kleijn²,

Richardson³

2019

Proceedings of the 5th World Congress on Mechanical, Chemical, and Material Engineering

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“…The energy balance and transport coefficients have a significant impact on arc pressure [28]. The thermodynamics study of plasma arc is the basis for studying heat transfer and flow in molten pool [29,30]. However, to our best knowledge, no one has studied how the exerted ultrasound affects the plasma transport coefficients until now.…”

Section: Introductionmentioning

confidence: 99%

Effects of Ultrasonic Vibration on the Transport Coefficients in Plasma Arc Welding

Chen

2020

Metals

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In ultrasound assisted plasma arc welding (U-PAW), the exerted ultrasonic vibration on the tungsten electrode interacts with the plasma arc and changes its heat-pressure characteristics. It is of great significance to investigate the underlying interaction mechanism. In this study, the calculation method of transport coefficients in U-PAW is developed. Translational thermal conductivity (including electrons thermal conductivity and the thermal conductivity of heavy particles) and electrical conductivity are calculated by considering the second-order approximation of Maxwell velocity distribution function, while the method of Butler et al. is adopted to calculate the reaction thermal conductivity in U-PAW. The effective value of the ultrasound velocity gradient tensor is employed to describe the effects of ultrasonic vibration on transport coefficients in ultrasound assisted plasma arc. The calculation results show that when the ultrasound is applied, the thermal conductivity of heavy particles in the plasma increases significantly and the electron thermal conductivity increases within some extent. The thermal conductivity of the reaction also increased to a great extent, and the electrical conductivity decreases a little bit. Although the thermal diffusion coefficient also has some increase, but the ordinary diffusion coefficient is obviously reduced due to the application of the ultrasound. With the updated transport coefficients, the plasma arc pressure on the anode surface is numerically computed, and the predicted pressures of PAW and U-PAW can be consistent with the measured ones.

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“…Using stainless steel as the welding material, Wu et al [9][10][11][12][13][14] developed a thermo-mechanical model to gain a better understanding of energy propagation and calculate the dynamic keyhole evolution and the fluid flow in the weld pool. Wu, Shinichi Tashino et al [15,16] investigated the weld pool convection and keyhole formation mechanism in the keyhole plasma arc welding (PAW). The experimental methods of the above numerical studies were PAW.…”

Section: Introductionmentioning

confidence: 99%

“…Therefore, numerical simulation analysis regarding to the material flow behavior of AA2219 weld pool has seldom been carried out. However, AA2219 has a high thermal conductivity, so it dissipates heat quickly in the welding process, and the keyhole of AA2219 is more hardly formed than that of steel or 5-Series aluminum alloy in VPPAW [15]. Therefore, it is important to study the material flow behavior of AA2219 during VPPAW.…”

Section: Introductionmentioning

confidence: 99%

“…VPPAW essentially belongs to perforated welding, and thus, the keyhole evolution is extremely important. Generally, the keyhole is formed in several seconds, which is proposed to be the dominant driving force of arc pressure [15]. The arc pressure model established at present mainly considers the change of current and the arc pressure distribution along the thickness direction of the workpiece [9,10,19,22].…”

Section: Introductionmentioning

confidence: 99%

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Prediction of the Weld Pool Stability by Material Flow Behavior of the Perforated Weld Pool

et al. 2020

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This article presents the application of a computational fluid dynamics (CFD) finite volume method (FVM) model for a thermo-mechanical coupling simulation of the weld pool used in variable polarity plasma arc welding (VPPAW). Based on the mechanism of the additional pressure produced through self-magnetic arc compression and the jet generated from mechanical plasma arc compression, and considering the influence of arc height and keyhole secondary compression on arc pressure, a three-dimensional transient model of variable polarity plasma arc (VPPA) arc pressure was established. The material flow behaviors of the perforated weld pools were studied. The results show that three kinds of flow behavior existed in the perforation weld pools and it is feasible to predict the weld pool stability by the material flow behaviors of the perforated weld pools. The weld pools can exist stably if the material flow in the bottom of the perforated weld pools can form confluences with moderate flow velocities of 0.45 m/s, 0.55 m/s and 0.60 m/s. The weld pools were cut when the material flowed downward and outward with the maximum velocity of 0.70 m/s, 0.80 m/s. When the maximum material flow velocity was 0.40 m/s, the weld pool collapsed downward under the action of larger gravity. The thermo-mechanical coupling model was verified by the comparison of the simulation and experimental results.

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Elucidation of the weld pool convection and keyhole formation mechanism in the keyhole plasma arc welding

Cited by 68 publications

References 31 publications

The Influence of Surface Deformation on Thermocapillary Flow Instabilities in Low Prandtl Melting Pools with Surfactants

The Influence of Surface Deformation on Thermocapillary Flow Instabilities in Low Prandtl Melting Pools with Surfactants

Effects of Ultrasonic Vibration on the Transport Coefficients in Plasma Arc Welding

Prediction of the Weld Pool Stability by Material Flow Behavior of the Perforated Weld Pool

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