Numerical study of heat transfer and solute distribution in hybrid laser-MIG welding

Chen, Xuyang; Yu, Gang; He, Xiuli; Li, Shaoxia; Li, Zhiyong

doi:10.1016/j.ijthermalsci.2019.106182

Cited by 24 publications

(5 citation statements)

References 32 publications

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“…Comparison of the simulated and observed melt pool is commonly used in the calibration of numerical model and of great significance in the modelling of heat and mass transfer inside melt pool. 14,15,[18][19][20] Both the simulated results obtained from HP-R and HR-R show good correspondence with the experimental results with a small relative error, however, the calculated dimension from HP-R is obviously more reasonable than that from HR-R because the error for HP-R is smaller according to the results. Taking the 20 mm/s situation for example, the experimentally observed melt width and melt depth are 1097 lm and 245 lm, respectively.…”

Section: Energy Transfer At Gas/liquid Surfacesupporting

confidence: 57%

“…The direct in-situ observation of the interface conditions for the melt pool with high temperature and complex dynamic characteristics imposes great challenges for the experimental observation methods and tools, and thus the numerical method has been developed, which can provide more details in a relatively easier way. [14][15] Here, the laser absorptance which characterizes the energy transfer, gas/liquid surface deformation related to driving force and boundary conditions for fluid flow, properties smooth used to describe the variation of mixture properties at substrate interface, and thermal contact condition for different materials considering the interface thermal transfer are analyzed to study their effects on heat and mass transfer. For the solid/liquid interface, the variation of solid/ liquid boundary is analyzed, but the UMZ is only qualitatively discussed and not studied in detail because its mechanism is still not revealed and will be further investigated in future.…”

Section: Introductionmentioning

confidence: 99%

“…9 As a result, both the heat transfer and fluid flow will be affected. Besides, concentration dilution is mainly driven by convection, 15 thus it is also expected to be affected by the free surface deformation. In several reported works, Esfahani et al 17 studied the alloy composition and fluid flow during dissimilar welding of carbon steel and stainless steel, and Volume of Fluid method (VOF) was used to capture the surface topography on the gas/liquid surface.…”

Section: Introductionmentioning

confidence: 99%

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Effects of interface conditions on heat and mass transfer during modeling of laser dissimilar welding

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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An improved 3 D heat and mass transfer model was developed to study the effects of interface conditions during modelling of laser dissimilar welding. In detail, the interface conditions consist of the physical processes at gas/liquid surface (e.g. free surface deformation and optical absorptance), substrate interface (e.g. mixture properties in liquid phase and thermal contact condition) and solid/liquid interface (e.g. fusion line). Their effects on heat and mass transfer are numerically and experimentally analyzed, which are all non-negligible in the welding modelling. In conclusion, free surface deformation influences convection flow and should be considered in the situation of micro-welding and high energy-input welding. Besides, the energy transfer between laser and substrate is more reasonably described by the optical absorptance expressed in polynomial function. The mass transfer induced variation of mixture properties is well described by the method based on time-dependent mixture fraction. Thermal resistance between clamp and substrate should be considered in the modelling of temperature field on macroscale. The joint conductance at substrate interface could be neglected when modelling heat and mass transfer inside the melt pool, while it should be calculated in the simulation of temperature distribution based on the mechanism of heat conduction. The obtained results in this paper provide a vital insight into the interface conditions in laser dissimilar welding process.

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Section: Energy Transfer At Gas/liquid Surfacesupporting

confidence: 57%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Effects of interface conditions on heat and mass transfer during modeling of laser dissimilar welding

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…6 The welding parameters also influence the geometry of the weld bead formation, developed microstructure, productivity, and cost of welded joints. 7,8 Conventionally metallurgical analysis is utilized to detect geometry and metallurgical changes of weld bead with welding parameters. However, few metallurgical analyses are destructive in nature and costly.…”

Section: Introductionmentioning

confidence: 99%

Finite element analysis and experimental investigation of moving heat source model for GMAW deposited mild steel weld bead

Aslam

Sahoo

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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An investigation has been done to identify the heat source model suitable for numerical modeling of the Gas Metal arc Welding (GMAW) welding process. In the present investigation, a numerical model was constructed to simulate the GMAW welding process through transient thermal analysis for different thermal heat source models for weld deposition of Mild steel considering semi-cylindrical weld bead geometry. The Gaussian heat source with radial coordinate system and double ellipsoidal thermal heat source have been considered to develop a Finite Element Analysis (FEA) model. Validation of numerical analysis results has been confirmed through experimental investigation. Numerical modeling confirms the utilization of both heat sources, i.e. Gaussian and Double ellipsoidal for the prediction of the weld bead deposition profile. However, the numerical modeling developed using a double ellipsoidal heat source has more resembles experimental investigation due to the utilization of bead profile data. However, the Gaussian heat source is found to be suitable in the case of the unavailability of experimental data. The experimental studies show a variation in the weld bead geometry, along its welding direction due to multiple environmental factors. The microstructural investigation also shows the development of a fine columnar grain structure at the welding bead & weld penetration zone, and the grain structure became coarser at the Heat Affected Zone (HAZ).

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“…Assisted by advanced auto-control technology, laser direct energy deposition (L-DED) was developed as a promising additive manufacturing method and is widely used to obtain a deposited metal layer on the surface of the base metal to improve its mechanical properties and service performance [1][2][3], such as the deposition of Co-based powders to 38MnVS. Compared with the traditional surface modification method, L-DED has the obvious advantages of higher efficiency, a smaller heat-affected zone, lower deformation and smaller residual stress [4][5][6]. The substrate and powders are heated and melted by high power density laser beam, and many complicated physical processes are included and coupled during the L-DED process, such as the interaction of substrate and liquid powders, phase change, heat and mass transfer inside the melt pool, solidification phenomenon and grain growth, which are all closely related to the fluid flow inside the melt pool [7][8][9][10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

Surface Tension-Driven Flow and Its Correlation with Mass Transfer during L-DED of Co-Based Powders

et al. 2022

Metals

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Laser direct energy deposition (L-DED) is one of the most promising additive manufacturing methods, which has been paid more and more attention in recent years. An improved heat and mass transfer model was developed here to analyze thermal behavior, driving force, surface tension-driven flow and its correlation with dilution during L-DED of Co-based powders to a 38MnVS substrate. Thermal behavior was firstly studied for its fundamental influence on fluid flow and mass transfer. Next, the roles of capillary force and thermal capillary force were characterized using both the dimensional analysis and simulation methods, and the mechanism of surface tension-driven flow was also qualitatively investigated. Finally, flow characteristics inside the melt pool were studied in detail and their correlation with the dilution phenomenon was analyzed based on the multi-component mass transfer model. The temperature gradient was found to be much larger at the front of the melt pool, and it took about 200 ms for the melt pool to reach a quasi-steady condition. Moreover, sharp changes in the curvature of the solid/liquid boundary were observed. Surface tension was demonstrated as the main driver for fluid flow and resulted in centrally outward Marangoni flow. Capillary force contributes to the reduction of the curvature of the free surface, and thermal capillary force (Marangoni force) dominated the Marangoni convection. Alloy elements from the powders, such as Co and Ni, were added to the front part of the melt pool and mainly diluted at the upper side of the rear region near the symmetric plane of the melt pool. Fundamental results in this work provide a valuable understanding of the surface tension-driven flow and its correlation with concentration dilution during the additive manufacturing process.

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Numerical study of heat transfer and solute distribution in hybrid laser-MIG welding

Cited by 24 publications

References 32 publications

Effects of interface conditions on heat and mass transfer during modeling of laser dissimilar welding

Effects of interface conditions on heat and mass transfer during modeling of laser dissimilar welding

Finite element analysis and experimental investigation of moving heat source model for GMAW deposited mild steel weld bead

Surface Tension-Driven Flow and Its Correlation with Mass Transfer during L-DED of Co-Based Powders

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