Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in...
Transcript of Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in...
![Page 1: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/1.jpg)
Modeling of Transport Phenomena in
Gas Tungsten Arc Welding of Ni to 304
Stainless Steel
Alireza Bahrami
Daryush K. Aidun
Mechanical and Aeronautical Engineering Department
COMSOL Conference
10/10/2013
1 Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 2: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/2.jpg)
2
Motivation
•Joining of dissimilar metals / alloys by using arc welding has been a challenge
in several industries such as power plants and offshore piping.
•Challenging physics behind the welding of dissimilar alloys is not yet well
understood, because of differences in the thermo-physical, mechanical, and
metallurgical properties.
For this reason to produce quality dissimilar welds, it is necessary to perform
mathematical / numerical modeling of transport phenomena in the weld pool
during melting & solidification.
Not only does modeling of the dissimilar welds provide a better understanding
of the physics behind it, but also is a more cost effective process to produce
high quality welds.
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 3: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/3.jpg)
Gas Tungsten Arc (GTA) welding
3
• An arc is established between a
tungsten electrode and the base
metal.
• Tungsten electrode is not a
consumable.
• An inert shielding gas protects
the weld from the atmosphere
(Welding Metallurgy; S. Kou; 2003)
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 4: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/4.jpg)
Transport phenomena
Weld zone shape and penetration
Dilution
Cooling rate (Thermal cycle)
Heat affected zone geometry / width
Thermal stress residues
Defect formation
4
Physics involved in the welding
process
Electromagnetics
Fluid flow
Heat transfer
Dissimilar welding
Different properties
Three dimensional
modeling
Mass transfer
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 5: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/5.jpg)
Convective Forces
• Buoyancy force
• Lorentz Force
• Marangoni effect
depends on dγ/dT
(Welding Metallurgy; S. Kou; 2003)
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 6: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/6.jpg)
Mathematical Formulations
Classic transport equations are solved for the domain
Momentum equation:
6 Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 7: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/7.jpg)
Mathematical Formulations
Marangoni effect:
Energy equation:
7 Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 8: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/8.jpg)
Material properties
• Solution properties:
• Surface tension:
8
For ρ, μ, β, k, Cp and σ
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 9: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/9.jpg)
9
For as =0.012 wt%
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 10: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/10.jpg)
Numerical Method
• Software: COMSOL Multi-Physics
• Physics :Electromagnetic Field, Fluid Flow and Heat transfer
• Mesh: Tetrahedral, 0.08 mm at Fluid and 1 mm at Solid Domain
mm
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 11: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/11.jpg)
Numerical vs Experimental Results
mm Ni
Steel
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 12: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/12.jpg)
Y
Top View of the FZ
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 13: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/13.jpg)
1018 BM 2205 BM
d
Side View of the FZ
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 14: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/14.jpg)
Temperature Distribution
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 15: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/15.jpg)
Conclusion
• Weld profile is asymmetric due to different melting
points.
• Higher Lorentz force in the Ni side pushes the fluid
towards the steel side.
• At the top surface flow is under Marangoni effect.
• Conductive heat transfer is higher in the Ni side;
therefore its temperature grows higher.
15 Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston
![Page 16: Transport Phenomena in GTA Welding of Dissimilar Ferrous ... · Modeling of Transport Phenomena in Gas Tungsten Arc Welding of Ni to 304 Stainless Steel Alireza Bahrami Daryush K.](https://reader031.fdocuments.us/reader031/viewer/2022041016/5ec8f1c18859ec39871c39e8/html5/thumbnails/16.jpg)
16
Thank You
Excerpt from the Proceedings of the 2013 COMSOL Conference in Boston