Simulation Study on Weld Formation in Full Penetration Laser + MIG Hybrid Welding of Copper Alloy

An, Feipeng; Gong, Qilong; Xu, Guoxiang; Zhang, Tan; Hu, Qingxian; Zhu, Jie

doi:10.3390/ma13235307

Cited by 4 publications

(3 citation statements)

References 34 publications

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“…In the numerical simulation of temperatures during welding, the heat exchange and cooling boundary conditions are the primary considerations. The convective heat transfer, influenced by temperature gradients and the inert gas acting on the plate, follows Newton’s law of cooling [ 47 ]. The heat bodies generate radiative heat transfer by absorbing laser light, which follows the Stefan-Boltzmann law [ 47 ].…”

Section: Finite Element Simulation Analysismentioning

confidence: 99%

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Research on the Low-Temperature Impact Toughness of a New 100-mm Ultra-Thick Offshore Steel Fabricated Using the Narrow-Gap Laser Wire Filling Welding Process

Hou,

Guo,

Wang

et al. 2024

Materials

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Ultra-thick offshore steel, known for its high strength, high toughness, and corrosion resistance, is commonly used in marine platforms and ship components. However, when offshore steel is in service for an extended period under conditions of high pressure, extreme cold, and high-frequency impact loads, the weld joints are prone to fatigue failure or even fractures. Addressing these issues, this study designed a narrow-gap laser wire filling welding process and successfully welded a 100-mm new type of ultra-thick offshore steel. Using finite element simulation, EBSD testing, SEM analysis, and impact experiments, this study investigates the weld’s microstructure, impact toughness, and fracture mechanisms. The research found that at −80 °C, the welded joint exhibited good impact toughness (>80 J), with the impact absorption energy on the surface of the weld being 217.7 J, similar to that of the base material (225.3 J), and the fracture mechanism was primarily a ductile fracture. The impact absorption energy in the core of the weld was 103.7 J, with the fracture mechanism mainly being a brittle fracture. The EBSD results indicated that due to the influence of the welding thermal cycle and the cooling effect of the narrow-gap process, the grains gradually coarsened from the surface of the welded plate to the core of the weld, which was the main reason for the decreased impact toughness at the joint core. This study demonstrates the feasibility of using narrow-gap laser wire filling welding for 100-mm new type ultra-thick offshore steel and provides a new approach for the joining of ultra-thick steel plates.

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Section: Finite Element Simulation Analysismentioning

confidence: 99%

“…The convective heat transfer, influenced by temperature gradients and the inert gas acting on the plate, follows Newton’s law of cooling [ 47 ]. The heat bodies generate radiative heat transfer by absorbing laser light, which follows the Stefan-Boltzmann law [ 47 ].…”

Section: Finite Element Simulation Analysismentioning

confidence: 99%

Research on the Low-Temperature Impact Toughness of a New 100-mm Ultra-Thick Offshore Steel Fabricated Using the Narrow-Gap Laser Wire Filling Welding Process

Hou,

Guo,

Wang

et al. 2024

Materials

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“…In terms of hybrid welding, Xu et al [21] represented the arc by using a double ellipsoid heat source and calculated the thermodynamic behavior of 6061 aluminum alloy T joint (thickness = 2 mm) by presetting the laser heat source under the arc source. An et al [22] achieved 3D transient modeling of the fully permeable hybrid Laser-MIG process with a 2-mm thick copper alloy sheet. As determined by their dynamic behavior analysis on the weld pool during hybrid welding, the stability of the hybrid welding lock hole root was greatly enhanced, the forming defects were effectively suppressed, and the sheet complete penetration butt welding became more reliable.…”

Section: Several Contemporary Scholars Have Undertaken Substantial Ex...mentioning

confidence: 99%

An improved simulation of temperature field in Laser–low current

Xu,

Sun,

Han

et al. 2024

Preprint

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This study aimed to achieve efficient and precise connection of thin steel sheets for vehicles by analyzing the thermal process of Laser-MAG hybrid high-speed welding lap of thin galvanized steel sheets. A high-speed camera combined with an NI AD data acquisition system were used, and the transition behavior and electrical signals of low-current MAG and Laser-MAG hybrid welding were examined. The thin sheet MAG welding droplet transition method mainly comprised short-circuit transfer. During the short-circuit phase, the voltage decreased and the current increased sharply, forming a short-circuit liquid column. When current increased to a certain level, the liquid bridge burst, the droplets carried heat and kinetic energy to the weld pool, the arc voltage returned to a no-load state, and the arc was re-ignited. In the arcing phase, the current first decreased steeply and then slowly, while the voltage decreased slowly and smoothly. According to the different heat source characteristics of the arc combustion and short-circuit stages during short-circuit transition, a new MAG heat source for low-current short-circuit transition was developed. This study employed a double-ellipse heat source with different powers for the arc combustion stage as well as a uniform body heat source that considered the thermal and kinetic energies of the melt droplets for the short-circuit stage. The thermal input of low current MAG welding was described by double-ellipse and uniform body heat source periodic loading. Moreover, the laser exerted an attraction and compression influence over the arc during the hybrid welding, which promoted the droplet transfer. Therefore, based on the novel MAG heat source, a hybrid Laser-MAG heat source in the short-circuit transition mode was developed. The laser beam heat source was described using a three-dimensional column heat source, the arc attraction and compression by the laser were considered indirectly through distribution parameter tuning for the double-ellipse model, and the laser-promoted transition effects of the droplets were described through the cycle frequency alterations of a double ellipsoid and homogeneous heat source. this heat source model was used to determine the MAG welding and hybrid welding temperature fields. Using hybrid Laser-MAG welding, a weld with a high depth-to-width ratio and complete penetration was obtained. The weld geometry and weld pool length were determined through welding tests, and the test results coincided with the fusion line trend and shape of the weld obtained by simulation, proving the rationality of the developed heat source model.

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A literature review in heat source thermal modeling applied to welding and similar processes

Nascimento

Magalhães

Paes

2023

Int J Adv Manuf Technol

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Simulation Study on Weld Formation in Full Penetration Laser + MIG Hybrid Welding of Copper Alloy

Cited by 4 publications

References 34 publications

Research on the Low-Temperature Impact Toughness of a New 100-mm Ultra-Thick Offshore Steel Fabricated Using the Narrow-Gap Laser Wire Filling Welding Process

Research on the Low-Temperature Impact Toughness of a New 100-mm Ultra-Thick Offshore Steel Fabricated Using the Narrow-Gap Laser Wire Filling Welding Process

An improved simulation of temperature field in Laser–low current

A literature review in heat source thermal modeling applied to welding and similar processes

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