An Integrated Modeling Approach for Predicting Process Maps of Residual Stress and Distortion in a Laser Weld: A Combine
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FUSION welding techniques have been utilized in the structural joining of safety-critical components across aerospace,[1] automotive,[2] and power generation[3,4] industries for many years, thanks to the considerable joint-integrity that they can offer, and their relatively low capital investment and production costs.[1] Whilst older welding methods such as tungsten inert gas (TIG) produce large weld pools and heat-affected zones[5] due to the size of the arc formed, the newer ‘‘high power-density’’ beam-type processes, such as laser welding, offer a much narrower fusion zone and heat-affected zone,[6] as the energy from the power source is much more focused. Welding simulation has been considered by academia and industry alike for many years; however, with the RICHARD P. TURNER, CHINNAPAT PANWISAWAS, YOGESH SOVANI, and BAMA PERUMAL, Research Fellows, R. MARK WARD, Senior Lecturer, HECTOR C. BASOALTO, PRISM Technical Director, and JEFFERY W. BROOKS, Hanson Professor of Industrial Metallurgy, are with the School of Metallurgy & Materials, University of Birmingham, Edgbaston, Birmingham, B15 2TT, UK. Contact e-mail: [email protected] Manuscript submitted May 25, 2016. Article published online July 11, 2016. 2954—VOLUME 47B, OCTOBER 2016
constantly increasing computational power available to the researcher, the details of the models and their outcomes have become more and more intricate over the years. Newer modeling methods, including multi-physics modeling which can take into account the solid, liquid, and vapor phases of materials, liquid flow lines, Marangoni forces, surface tension effects, buoyancy effects and compressible or incompressible fluids have been developed and utilized. The computational fluid dynamics (CFD) approach is used to simulate the interaction of the heat source and the materials considering the transition between liquid and solid states as well as between the liquid and vapor states. These solid-liquid and liquid-gas interfacial conditions are of importance to be comprehensively understood as they can contribute to the formation of residual stresses and distortions during the welding operation. Over the last two decades, literature has been reported on sophisticated modeling approaches[7–12] and experimental techniques[13–18] to study the dynamics of the keyhole phenomena during high power density fusion welding technologies, such as laser welding. From a modeling perspective, the interface deformation that leads to keyhole formation during the laser welding has been studied intensively using various numerical techniques, including a volume-of-fluid approach[13,14] and a level set
METALLURGICAL AND MATERIALS TRANSACTIONS B
Fig. 1—Outputted weld pool shape from the CFD OpenFOAM model. As seen at an isometric angle, and analyzing a cross section perpendicular to the direction of travel.
method.[9] Recently, Courtois et al.[9] have proposed a level set approach and included the influence of the electromagnetic field to accurately capture the energy reflection inside the keyhole. However, the me
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