Investigation on automated loading of dynamic 3D heat source model for welding simulation

Since programing complex and dynamic heat source model for welding simulation is a complex job,the parametric methods are studied in this paper.Firstly,an overall flow to achieve automatically modeling welding was introduced.Secondly,an expert module rule for selecting welding heat source model was founded,which is based on simulation knowledge and experiences.Thirdly,a modularity routine method was investigated using writing with C++programing,which automatically creates subroutines of 3D dynamic heat source model for user.To realize the dynamic weld path,the local weld path coordinate system was moved in the global coordinate system and it is used to model the direction of weld gun,welding path and welding pose.The weld path data file was prepared by the automatic tool for the welding heat source subroutines.All above functions were integrated in the user interface and the connection with architecture was introduced.At last,a laser beam welding heat source modeling was automatically modeled and the weld pool geometry was compared with the reported literature.It demonstrated that the automated tool is valid for welding simulation.Since modeling became convenient for welding simulation using the tool proposed,it could be easy and useful for welding engineers to acquire the needed information.

COMPUTERIZED SIMULATION AND EXPERIMENTAL RESEARCH ON SOFT-SWITCHING ARC WELDING INVERTER POWER SOURCE

Based on the existing component models in the Pspice software package, a combined model for Insulat- ed the Bipolar Transistor (IGBT) is established, in which a non - linear is introduced to represent the parasitic capacitance. Using this model, computerized simulation is conducted for the FB - ZVZCS - PWM soft - ewitching converter,the switching and energy-transferring characteristics of the components are analyzed.The simulation results are testified by experiments.It is proved that by abopting appropriate models,computerized simulation becomes an effective tool for investigation of arc welding inverter power source.

DEVELOPMENT AND APPLICATION OF ADAPTIVE MESH TECHNIQUE IN THREE DIMENSIONAL NUMERICAL SIMULATION OF WELDING PROCESS

The adaptive mesh mesh technique is developed and applied in three dimensional numerical simulation of welding process on the base of the commercial software. Special user subroutine is worked out to accom- plish this function.This technique can make the dense mesh moving simultaneously with the heat source while the other area of the structure with much coarser mesh, greatly reducing the number of nodes and elements in the analysis.Temperature field,displacement and stress distributions during welding pro- cess me analyzed by FEM method with adaptive mesh and the analysis is also conducted with normal FEM method. The temperature field,displacement and stress distributions obtained with both methods are shown in contrast. The results show that the temperature fields and the displacement distributions of simulation on adaptive mesh correspond wery well with that of without adaptive mesh. Though the stress distributions have some difference,but the trends of the stress distribution are corresponding.The com- parison of the computing time of the two meshes indicates that the adaptive that the adaptive mesh can greatly reduce the calculation time when used for welding process.

A customized system for simulation of welding thermal process

This paper presents a customized simulation system for analyzing welding temperature field, which is based on Finite elementary Analysis software MSC. Marc. The system has the functions of robustly hexahedral meshing, automated loading of dynamic heat source models for various welding methods and convenient post-processing for welding temperature field. A gene unit algorithm is presented to achieve robust simulation for assembled structure. High order routine method is used to generate various customized routines robustly, which includes Fortran subroutines for welding heat source, Marc command routines for automated modeling, and python subroutines for post-processing etc. With the system, simulation of welding temperature fields can be easily conducted with simple operations.

SIMULATION STUDY ON CAPACITOR DISCHARGE PERCUSION WELDING

Based on the network theory, the discharge circuit model of capacitor discharge percussion welding machine is established. The discharge current waveform is calculated by means of simulation method. A thorough inquiry into the factors affecting the discharge current waveform is made by using orthogonal design method. Results show that the calculation results of the calculation program proposed well coincide with the actual experiment data.

Study on Welding-Bead Bonding Strength of Laser-Stacking Copper-Aluminum Heterogeneous Electrode Plates

In this paper,two types of copper-aluminum heterogeneous electrode plates are stacked and the finite element analysis(FEA)models of two different laser welding conditions are built by using SYSWELD welding simulation software to calculate the depth of the welding bead and the temperature distribution of the welding surface.Then,the residual stress analysis data of the welded area are exported and the residual stress is applied to the welded specimen for CAE analysis to ensure that the welding bonding strength meets the design target of a shear force of 500 N or higher.The copper-aluminum laser-stacking simulation technique in this paper can be applied to the manufacturing of copper-aluminum heterogeneous laser-welded electrodes and series-connected electrodes of automotive lithium-ion power battery modules,providing an effective analysis method for welding bonding-strength.

SIMULATION OF WELD THERMAL CYCLE USING THE MODEL OF CARBONITRIDE PARTICLES PRECIPITATION

Based on the chasteal nucleation theory, the kinetic precipitation model of carbon - nitride particles in weld HAZ is proposed. Using the model,welding simulation technology and the quantitative metallo- graphic analysis,the precipitation transformation temperatue (PTT) curve is obtained.The data from the simulated welds are in good apreement with the value that the PTT curves predicated.

NUMERICAL SIMULATION OF PENETRATION PROCESS BASED ON THE VARIATION OF HEAT TRANSFER CONDITION

In this paper, the process of dynamic heat output in a welding pool and the variation of the penetration caused by the section change of the workpiece are analyzed using numerical simulation technique of thermal field. It is concluded that the variation of temperature gradient in HAZ along the length and width direction reflects the heat output of the welding pool, and that the output of the welding pool has a homogenous relationship to the pool penetration.

STUDY OF THE MICROSTRUCTURE AND PROPERTIES OF SIMULATED HEAT AFFECTED ZONE IN LASER WELDING OF ULCB 600 STEEL

The microstructure and properties of stmulated heat affected zone (HAZ) of laser welded ULCB600 steel were investigate by applying the simulation technique with gleeble - 2000 dynamic thermal - me - chanical simulator.The influence of the preheat condition on the microstructure and properties of simu- lated HAZ of laser welded plate was also studied in order to evaluate the feasibility of reducing arisk that the ductility and toedness of HAZ may be poor by using preheat treatment.The results indicate that the grain size of laser - welded HAZ simulated is very small no matter if there is preheat, the toughness of simulated HAZ is therefore improved comparing to the base metal,and there is no obvious brittle - ductile transition in the range from - 80℃ to 20℃. The TEM analyses of sub -microstruc- ture also discover that microstructure constituent of both simulated HAZ is dominative lath martensite. However, the shaf of martensite is relatively coarse,and the dislocation density is relatively high for simulated HAZ with 200℃ preheat because of slower cooling rate. Combination of these tow factors is responsible for farer bardness and better toughness of simulated HAZ with preheat condition.

Mathematical model and simulation of partial penetrated weld pool

The qualitative analysis on the behavior of partial penetrated weld pool transferring from pulsed peak current to base current in pulsed TIG welding is carried out in this paper. Based on the analysis results, the mathematical models for 3D liquid surface shape of partial penetrated weld pool in pulsed TIG welding are created including surface potential energy model, gravitational energy model and volumetric potential energy. The numerical simulation with these models and the experiments on low carbon steel are carried out using the software Surface Evolver. The simulation results and model are then amended with experimental results. Two important characteristic quantities, the liquid metal coverage ratio and the stripping width of liquid metal, are put forward in this paper, which paves a way for further weld pool full penetration control.

SIMULATION OF ROLL-FORMING PROCESSES OF WELDED PIPE

A multi- pumose simulation method for the roll- formign is proposed. The forming pro- cesses of welded pipes are systematically simulated by using the method. The three-dimensional cu rved surfaces of sheet metals in forming processes are mathema tically expressed by using the shape fonction S(X) which represents flow pattern of each part of sheet metal. Through optimis- ing t e parameter n in s(X), the best approximation of the deformation of sheet metal is derived and the minimum power of deformation is obtained. A mathematical procedure of this analysis is systematically foimulated. The simulation method can be applied to the analysis and simulation for various roll- forming processes of welded pipes observed in commercial production line.

Microstructure and Property of Coarse Grain HAZ X80 Pipeline Steel

The coarse grain HAZ microstructure and property of X80 pipeline steel with different carbon content was investigated. The weld thermal simulation test was carried out on Gleeble 1500 thermal mechanical test machine. The Charpy tests were completed at --20 ℃ for evaluating the toughness of coarse grain heat affected zone （CGHAZ）. The microstructure was examined by optical microscope （OM） and transmission electron microscopy （TEM）, and the austenite constituent was quantified by X-ray diffraction. The results showed that the ultra-low carbon can improve the toughness of CGHAZ by suppressing the formation of carbide, decreasing the martensite austenite （M-A） constituent and increasing the residual austenite in the M A.

Effects of Carbon on the CG HAZ Toughness and Transformation of X80 Pipeline Steel

X80 pipeline steel produced by TMCP has high strength and high toughness with ultrafine grain microstructure. The mi-crostructure coarsens and the toughness worsens at the coarse grained (CG) HAZ apparently after weld simulation. The experimental results indicated that the bainitic ferrite and the second phases formed at cooling are differently as the variation of carbon in base metal. In low carbon steels, the bainitic ferrite laths are long and narrow, the second phases are complex including residual austenite, martensite, the M-A constituent and the Fe3C carbide. The formation of Fe3C carbide is the main reason of the poor toughness in CG HAZ. The ultralow carbon in base metal, however, can improve the CG HAZ toughness through restraining the formation of carbides, decreasing the M-A constituent, increasing the residual austenite content, which are beneficial to the CG HAZ toughness.

INFLUENCE OF THE SECOND THERMAL CYCLE ON COARSE- GRAINED ZONE TOUGHNESS OF X70 STEEL

The influence of the second thermal cycle on coarse grained zone (CGHAZ) toughness of X70 steel is studied by weld thermal simulation test, scanning electron microscope and electron microprobe. The results show that the CGHAZ toughness is improved after the second thermal cycle but being heated during the intercritical HAZ (ICHAZ). The CGHAZ toughness decreases evidently after being heated during partially transformed zone, which chiefly results from the carbon segregation to the grain boundaries of primal austenite, thus forming high carbon martensite austenite (M A) constituent and bringing serious intercritically reheated coarse grain HAZ (IRCGHAZ) embrittlement.

Computational fluid dynamics simulation of friction stir welding:A comparative study on different frictional boundary conditions

Numerical simulation based on computational fluid dynamics （CFD） is a useful approach for quantitatively investigating the underlying thermal-mechanical conditions during FSW, such as temperature field and material deformation field. One of the critical issues in CFD simulation of FSW is the use of the frictional boundary condition, which represents the friction between the welding tool and the workpiece in the numerical models. In this study, three-dimensional numerical simulation is conducted to analyze the heat transfer and plastic deformation behaviors during the FSW of AA2024. For comparison purposes, both the boundary velocity （BV） models and the boundary shear stress （BSS） models are employed in order to assess their performances in predicting the temperature and material deformation in FSW. It is interesting to note that different boundary conditions yield similar predictions on temperature, but quite different predictions on material deformation. The numerical predictions are compared with the experimental results. The predicted deformation zone geometry by the BSS model is consistent with the experimental results while there is large difference between the predictions by the BV models and the experimental measurements. The fact that the BSS model yields more reasonable predictions on the deformation zone geometry is attributed to its capacity to automatically adjust the contact state at the tool/workpiece interface. Based on the favorable predictions on both the temperature field and the material deformation field, the BSS model is suggested to have a better performance in numerical simulation of FSW than the BV model.

INFLUENCE OF LOCAL BRITTLE ZONE ON THE FRACTURETOUGHNESS OF HIGH-STRENGTH LOW-ALLOYEDMULTIPASS WELD METALS

In this paper, toughness properties and microstructurc of low-alloyed multipass welds with yield strength above 700MPa have 6een studied using the weld thermal simulation and throughout thickness CTOD fracture mechanics tests. Impact testing of thermal simulated specimens showed that the primary weld metal and the fine gmmed weld metal had good toughness, while the coarse grained weld metal had the lowest toughness value as the local brittle zone (LBZ) in multipass weld metals. Cleavage fracture in CTOD testing of thick multipass weld metals was initiated from martensite-austenite (MA) phases in the LBZ. MA phases were distributed at the prior austenite grain boundaries and around ferrite grains. As the size of the local brittle zone along the fatigue crack front increases, CTOD frncture toughness of multipass weld metals decreases. The weakest link theory was used to evaluate effect of the local brittle zone on fracture toughness of thick multipass weld metals. The estimated curves agree well with the eaperimental data.

The Influence of Longitudinal Magnetic Field on the CO_2 Arc Shape

The COarc welding was carried out under a longitudinal magnetic field,and the arc shape has been studied by using a high-speed camera.From the camera images,we know that under the action of the longitudinal magnetic field,the upper end of the arc will constrict and the lower end of the arc will expand.It would become a bell-type shape and rotate at a highspeed in the optimum range of magnetic field parameters.The arc shape was simulated using a mathematical model,which was established based on experiment data and theoretical knowledge,and mechanism analysis has been carried out regarding the effect of longitudinal magnetic field on COwelding arcs.

Modeling transient fluid flow and heat transfer phenothena in stationary pulsed current TIG weld pool

A mathematical model is presented to describe transient behavior of heat transfer and fluid flow in stationary pulsed current tungsten inert gas (PC-TIG) weld pool, which considers three kinds of driving, forces for weld pool convection, i,e. buoyancyforce, electromagnetic force and surface tension force. furthermore. the effect of vaporization heat flux at the free surface of weld pool and the temperature coefficient of surface tenston which is a function of temperatuer and composition are considered in the model In order to accelerate the convergence of iteration the AST(additive source term)method which concerns with the thermal energv boundary conditions is extended successfully to deal with the momentum boundary conditions by which the transient momentum equation and energy equation are mutually coupled. At the same time. ADI (Alternating direction implicit) method and DBC (double blocks correction) technque are employed to solve the finite difference equations. The results of numerical simulation demonstrate the transient behavior of PC-TIG weld pool, as well as the periodic variation of fluid flow and heat transfer with the periodic variation of welding current in stationary PC-TIG weld pool. The theoretical predictions based on this model are, shown to be in good accordance with the experimental measurements.

A Computer Aided System for Simulating Weld Metal Solidification Crack

A computer-aided system for simulating weld solidification crack has been developed by which a welding engineer can carry out the welding solidification crack simulation on the basis of a commercial finite element analysis software package. its main functions include calculating the heat generations of the moving arc. mesh generation, calculating stress-strain distributions with element rebirth technique.

Numerical sensitivity analysis of welding-induced residual stress depending on variations in continuous cooling transformation behavior

The usage of continuous cooling transformation （CCT） diagrams in numerical welding simulations is state of the art. Nevertheless, specifications provide limits in chemical composition of materials which result in different CCT behavior and CCT diagrams, respectively. Therefore, it is necessary to analyze the influence of variations in CCT diagrams on the developing residual stresses. In the present paper, four CCT diagrams and their effect on numerical calculation of residual stresses are investigated for the widely used structural steel S355J2 ＋ N welded by the gas metal arc welding （GMAW） process. Rather than performing an arbitrary adjustment of CCT behavior, four justifiable data sets were used as input to the numerical calculation： data available in the Sysweld database, experimental data acquired through Gleeble dilatometry tests, and TTTICCT predictions calculated from the JMatPro and Edison Welding Institute （EWI） Virtual Joining Portal software. The performed numerical analyses resulted in noticeable deviations in residual stresses considering the different CCT diagrams. Furthermore, possibilities to improve the prediction of distortions and residual stress based on CCT behavior are discussed.