Numerical Simulation and Experimental Research on Temperature Distribution of Fillet Welds

Abstract

In this paper, a matrix equation for the welding heat source model was proposed to calculate the fillet welds temperature distribution based on the penetration depth and molten width. A double ellipsoid heat source model of fillet weld was established firstly by physical experiment and simulation calculation, and then the orthogonal experiment was constructed based on the previous calculation methods and experimentally measured data. Finally, the matrix equation of the heat source model parameters was obtained by regression analysis based on the joint penetration and width. The experimental and numerical simulation of the temperature distribution had been performed for the fillet weld and the results show that (1) the heat flux increases in one direction, while, oppositely, it decreased in another direction; (2) simulation results were highly in accordance with experiments results. The results indicated that the double ellipsoidal heat source model calculated by the matrix equation is quite appropriate for predicting the transient temperature distribution on the fillet welds for the gas metal arc welding process.Materials 2020, 13, 1222 2 of 11 for calculating residual stress, deformation, and solidification [16,17]. First of all, the premise of obtaining an accurate temperature field was to formulate a heat source model that was consistent with the actual situation. A welding heat source model was established by Rosenthal's application of Fourier's law (that is, point, line, and surface heat sources), which could reasonably calculate the transient temperature distribution at a certain distance from the heat source. Rosenthal's analysis, however, is less accurate for the temperature in or near the fusion and heat-affected zones because the scheme defined that the physical properties of the material did not change with temperature. To overcome most of these limitations, other forms of heat source models have been proposed. It was worth mentioning that the double ellipsoid heat source model was proposed by Goldak, which could well describe the arc welding heat source model [18].Due to the development of computers, welding numerical simulations has made great progress [19]. A 3-D heat transfer model has been established by Kim et al., in which the temperature, weld pool shape, and the weld pool reinforcement surface during gas-metal arc fillet welding were analyzed. In the establishment of this model, not only the heat transfer from the welding arc was considered, but also the thermal effect of metal droplets was considered by the volume heat source [20]. By summarizing the calculation of the temperature field of the predecessors, the transient temperature analytical equation of the semi-infinite body under the three-dimensional motion heat source was obtained by Fachinotti et al. [21]. Winczek applied the bimodal heat source model to establish a temperature field analytical model, which could well analyze the temperature of the multi-pass GMAW in the infinite body model [22].Some scholars have proposed some methods...

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