Numerical simulation of keyhole morphology and molten pool flow behavior in aluminum alloy electron-beam welding

Liu, Junpeng; Shu, Xi; Gu, Hua; Zhang, Binggang

doi:10.1016/j.ijheatmasstransfer.2019.04.112

Cited by 44 publications

(9 citation statements)

References 20 publications

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“…This was probably caused by lower welding speed and the resulting higher heat input during EBW, which allowed more metastable dissolved hydrogen to recombine at the solid–liquid interface. Since the flow velocity of the melt is lower at the edge of a melt pool than near the keyhole, [ 19 ] outgassing slowed down and the gas bubbles remained as pores after solidification.…”

Section: Resultsmentioning

confidence: 99%

Investigation of Pore Reduction in Hybrid Joints of Conventionally and Additively Manufactured AlSi10Mg Using Electron Beam Welding

Michler

Hollmann

Zenker³

et al. 2021

Adv Eng Mater

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Laser powder bed fusion (LPBF) is particularly well suited for the production of geometrically complex functional metal components. However, the size of the components that can be produced is limited technologically by the volume of the construction chamber, and economically by the low build‐up rates. With the provision of a reliable welding technology, size limitations can potentially be overcome to a degree by joining two additively manufactured (AM) components or by hybrid construction of components. Therefore, this study investigates the production of hybrid joints from additively and conventionally manufactured AlSi10Mg material by electron beam welding (EBW). It is known that EBW of LPBF‐processed aluminum alloys in the keyhole welding mode results in the distinctive formation of pores in the weld seams. To avoid this, two different joining strategies are pursued, namely, beam offset and multispot welding methods. It is thus determined that an adequate weld seam quality can only be achieved by means of a three‐spot welding process with adapted EB parameters. Accordingly, the investigations prove the applicability of the EB keyhole welding mode in EBW for the production of low‐porosity LPBF mixed joints.

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Section: Resultsmentioning

confidence: 99%

Investigation of Pore Reduction in Hybrid Joints of Conventionally and Additively Manufactured AlSi10Mg Using Electron Beam Welding

Michler

Hollmann

Zenker³

et al. 2021

Adv Eng Mater

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“…When welding magnesium alloy plates with EBW, as the temperature rises rapidly, the metal melts and then reaches the boiling point. Because the boiling point of Mg (1090 °C) is lower than that of Y (3345 °C), Zr (4409 °C), Nd (3100 °C) and Gd (3250 °C) [15], the evaporation of magnesium are more serious in high-temperature molten pool [16]. The enrichment of RE elements can hinder the growth of α-Mg grains, further play the role of refining grains in the welding area, and improve the mechanical properties of WE43 magnesium alloy welded joint [17].…”

Section: Microstructure Analysis Of the Weldmentioning

confidence: 98%

Microstructure and properties of vacuum electron beam welded WE43 magnesium alloy joint

Sheng

Zhang

et al. 2022

SN Appl. Sci.

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This study presents the microstructure and properties of vacuum electron beam welded WE43 magnesium alloy joint. The process parameters of acceleration voltage 150 kV, electron beam current 120 mA and welding speed 35 mm/s are used for vacuum electron beam welding of WE43 rare earth magnesium alloy plate. In this study, the main compositions of the weld are α-Mg and a small amount of eutectic rare earth phase β-Mg24Y5. The mass fraction of the rare earth phase β-Mg24Y5 in the weld area is more than that of the base metal. Segregation of Zr-rich particles can occur in weld zone. The average hardness of the weld is about 27% higher than that of the base metal, and the hardness near the center line of the weld is the highest. The yield strength, tensile strength and elongation of the joint are higher than that of the base metal by approximately 17%, 14% and 41%. Tensile fracture morphology of the welded joint is characterized by ductile and brittle mixed fracture. So, electron beam welding can achieve the connection of WE43 magnesium alloy plate with excellent microstructure and performance. It may be of great significance for this study to expand the application of rare earth magnesium alloy.

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“…The melting and vaporization enthalpies are source terms, the energy conservation equation uses the electron beam heat source, and the momentum conservation equation takes various forces including surface tension, buoyancy, electron beam impact, and metal vapor recoil as the momentum source terms. The specific equations: where ρ, u, t, p, η, F st , F m , F re , g, E, λ, T, Q V , Q evap, and F represent density, velocity, time, pressure, kinetic viscosity, surface tension, Marangoni shear, recoil pressure, gravitational acceleration, internal energy, thermal conductivity, temperature, volumetric heat source, evaporation energy transfer rate and volume fraction respectively [6][7][8].…”

Section: Governing Equationsmentioning

confidence: 99%

Numerical simulation study of electron beam welding of 2219 aluminium alloy

Ning,

Liu,

Liu

et al. 2023

J. Phys.: Conf. Ser.

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In arrange to consider the morphology of the weld seam of 2219 aluminium alloy electron beam welding as well as to obtain a well-formed welded joint, FLUENT software was adopted to electron beam welding numerically simulate the temperature field of 10 mm thick 2219 aluminium alloy. Along with the welding, the keyhole and temperature field of the molten pool changes constantly. The findings demonstrate that the liquid metal beneath the combined activity of recoil pressure and Marangoni convection causes the molten pool width to always increment and the depth to rise fast during the evolution of the keyhole and temperature field. The profundity and breadth of the liquid pool do not rise significantly at the same time when the energy of the fluid metal decays to a specific value, and the liquid pool has been in a steady oscillation state.

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Numerical simulation of keyhole morphology and molten pool flow behavior in aluminum alloy electron-beam welding

Cited by 44 publications

References 20 publications

Investigation of Pore Reduction in Hybrid Joints of Conventionally and Additively Manufactured AlSi10Mg Using Electron Beam Welding

Investigation of Pore Reduction in Hybrid Joints of Conventionally and Additively Manufactured AlSi10Mg Using Electron Beam Welding

Microstructure and properties of vacuum electron beam welded WE43 magnesium alloy joint

Numerical simulation study of electron beam welding of 2219 aluminium alloy

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