Numerical simulation of dynamic development of keyhole in double-sided arc welding

Wu, Chuansong; Sun, Juntao; Zhang, Y M

doi:10.1088/0965-0393/12/3/005

Cited by 8 publications

(3 citation statements)

References 15 publications

(28 reference statements)

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“…In a study on the force on the keyhole wall, C.S. Wu and R. Kovacevic [9,10] believe that the force driving the formation of the keyhole is the metal vapor recoil pressure. In addition, the keyhole wall is also affected by the Marangoni shear force caused by the surface tension gradient.…”

Section: Introductionmentioning

confidence: 99%

Simulation of the Effect of Keyhole Instability on Porosity during the Deep Penetration Laser Welding Process

Kang¹,

Zhao²,

Li³

et al. 2022

Metals

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The quality of a laser deep penetration welding joint is closely related to porosity. However, the keyhole stability seriously affects the formation of porosity during the laser welding process. In this paper, a three-dimensional laser welding model with gas/liquid interface evolution characteristics is constructed based on the hydrodynamic interaction between the keyhole and molten pool during the laser welding process. The established model is used to simulate the flow and heat transfer process of molten. The Volume of Fluid (VOF) method is used to study the formation and collapse of the keyhole and the formation of bubbles. It is found that bubbles are easy to form when the keyhole depth abruptly changes. There are three main forms of bubbles formed by keyhole instability. The front wall of the keyhole collapses backward to form a bubble. The back wall of the keyhole inclines forward to form a bubble. The lower part of the keyhole produces a necking-down effect, and the lower part of the keyhole is isolated separately to form a bubble. In addition, when the keyhole does not penetrate the base metal, the stability of the keyhole is high and the percentage of porosity is low.

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Section: Introductionmentioning

confidence: 99%

Simulation of the Effect of Keyhole Instability on Porosity during the Deep Penetration Laser Welding Process

Kang¹,

Zhao²,

Li³

et al. 2022

Metals

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“…Gao [7] investigated the distributions of fluid flow and temperature field in double-sided GTA process. Wu [8,9] and Sun [10,11] developed a numerical model to analyse and simulate the dynamic keyhole establishment process during the keyhole DSAW process, which is based on the heat transfer model without considering the fluid flow in the weld pool.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of fluid flow and temperature field in keyhole double‐sided arc welding process on stainless steel

Dong

Gao

2005

Numerical Meth Engineering

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SUMMARYDouble-sided arc welding process powered by a single supply is a type of novel high-production process. In comparison with the conventional single-sided arc welding, this process has remarkable advantages in enhancing penetration, minimizing distortion and improving welding production. In this paper, a three-dimensional steady numerical model is developed for the heat transfer and fluid flow in plasma arc (PA)-gas tungsten arc (GTA) double-sided keyhole welding process. The model considers the surface tension gradient, electromagnetic force and buoyancy force. A CCD camera is used to observe the size and shape of the keyhole and weld pool. The acquired images are analysed through image processing to obtain the surface diameters of the keyhole on the two sides. A double-V-shaped keyhole geometry is then proposed and its characteristic parameters are derived from the images and cross-section of weld bead. In the numerical model, the keyhole cavum within the weld pool is treated as a whole quality, whose temperature is fixed at the boiling point of the workpiece material. The heat exchange between the keyhole and weld pool is treated as an interior boundary of the workpiece. Based on the numerical model, the distributions of the fluid flow and temperature field are calculated. A comparison of cross-section of the weld bead with the experimental result shows that the numerical model's accuracy is reasonable.

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“…Wu developed a numerical model to investigate heat transfer in PA-GTA double-sided welding process [12], and the dynamic development of keyhole in DSAW was also numerically simulated [13]. Both the researches of [12] and [13] were based on heat transfer without considering the fluid flow in the weld pool.…”

Section: Introductionmentioning

confidence: 99%

Heat transfer and fluid flow in fusion type PA-GTA double-sided welding

Dong

Gao

2005

Modelling Simul. Mater. Sci. Eng.

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In comparison with conventional single-sided arc welding, double-sided arc welding powered by a single power supply has remarkable advantages in enhancing penetration, minimizing distortion and improving welding production. In this paper, a three-dimensional steady numerical model is developed for the heat transfer and fluid flow in a fusion type plasma arc (PA)–gas tungsten arc (GTA) double-sided welding process. Based on the numerical model, the distributions of the fluid flow and temperature field are calculated. Numerical results show that the peak temperature and temperature gradient in the weld pool in the PA side are higher than the values in the GTA side. Within the weld pool, the electromagnetic force drives the melted metal to move from two sides to the central part of the weld pool, and this effect is positive to penetrating the workpiece. The fluid flow of the melted metal in the free surface of the weld pool is fiercer than the flow within the weld pool, and the biggest flow velocity of the melted metal occurs in the free surface in the PA side. A comparison of the cross section of the weld bead with the experimental result shows that the numerical model's accuracy is reasonable.

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Numerical simulation of dynamic development of keyhole in double-sided arc welding

Cited by 8 publications

References 15 publications

Simulation of the Effect of Keyhole Instability on Porosity during the Deep Penetration Laser Welding Process

Simulation of the Effect of Keyhole Instability on Porosity during the Deep Penetration Laser Welding Process

Numerical simulation of fluid flow and temperature field in keyhole double‐sided arc welding process on stainless steel

Heat transfer and fluid flow in fusion type PA-GTA double-sided welding

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