Numerical analysis of heat transfer process for double sided tungsten inert gas – metal inert gas weld pool

Abstract

Double sided arc welding is a new type of technology developed in recent years. Many experiments show that this technology has great advantages over single arc welding for the joining of intermediate thickness stainless steel and aluminium alloy base metals. In the present work, a three-dimensional transient numerical model is created to reveal the heat transfer process for a double sided tungsten inert gas (TIG) - metal inert gas (MIG) weld pool from the viewpoint of heat transfer literature and hydrodynamics. Considering of the features of the model, effective calculation software using finite element technology is adopted. The temperature fields in the weld pool for double sided TIG - MIG welding are successfully calculated; in addition, the configuration of the weld pool is also calculated.Comparisons show that thecalculatedresults agree approximately with the experimentally measured results. STWJ/310     

Superplastic forming gas pressure of titanium alloy bellows

The complex superplastic forming (SPF) technology applying gas pressure and compressive axial load is an advanced forming method for titanium alloy bellows, whose forming process consists of the three main forming phases namely bulging, clamping and calibrating phase. The influence of forming gas pressure in various phases on the forming process was analyzed and the models of forming gas pressure for bellows were derived according to the thin shell theory and the plasticity deformation theory. Using the model values, taking a two-convolution DN250 Ti-6Al-4V titanium alloy bellows as an example, a series of superplastic forming tests were performed to evaluate the influence of the variation of forming gas pressure on the forming process. According to the experimental results these models were corrected to make the forming gas pressures prediction more accurate.     

Numerical simulation of gas metal arc welding temperature field

The infrared camera is used to investigate the temperature field of gas metal arc welding.The results show that the temperature distribution of weld pool and adjacent area appears cone shape.A new heat source model combined by Gaussian distribution heat source of the arc and conical distribution heat source of the droplet is set up based on the experimental results, and with the combined boundary conditions,the temperature field of gas metal arc welding is simulated using finite element method.According to the comparison between the results of experiment and simulation in temperature field shows that the new combined heat source model is more accurate and effective than the Gauss heat source model.     

Melt metal sheet breaking mechanism of close-coupled gas atomization

The gas atomization is the process that a liquid mass is disintegrated into a collection of liquid melt droplets by the impact of high velocity gas stream and solidified into metal particles. However, the liquid melt sheet breaking mechanism has not been fully understood. So the experimental research was carried out under the condition of lower melt superheat. The results reveal that there are three approaches about melt metal sheet＇s breakage： from the edges of sheets, from inner surface of sheets, and disrupted by other droplets and sheets. The approach of melt sheet breakage is dependent on its thickness. The thicker sheets （above 25μm） are disintegrated mainly by the way of droplet＇s departing from edges, and the thinner sheets （below 10 μm） are chiefly breaking from the inner surface.     

Modeling corrosion behavior of gas tungsten arc welded titanium alloy

The pitting corrosion characteristics of pulse TIG welded Ti-6Al-4V titanium alloy in marine environment were explained. Besides the rapid advance of titanium metallurgy, this is also due to the successful solution of problems associated with the development of titanium alloy welding. The preferred welding process of titanium alloy is frequently gas tungsten arc（GTA） welding due to its comparatively easier applicability and better economy. In the case of single pass GTA welding of thinner section of this alloy, the pulsed current has been found beneficial due to its advantages over the conventional continuous current process. The benefit of the process is utilized to obtain better quality titanium weldments. Four factors, five levels, central composite, rotatable design matrix are used to optimize the required number of experiments. The mathematical models have been developed by response surface method（RSM）. The results reveal that the titanium alloy can form a protective scale in marine environment and is resistant to pitting corrosion. Experimental results are provided to illustrate the proposed approach.     

Fabrication of AIN-TiC/Al composites by gas injection processing

The fabrication of AlN-TiC/Al composites by carbon- and nitrogen-containing gas injection into Al-Mg-Ti melts was studied. It was shown that AlN and TiC particles could be formed by the in situ reaction of mixture gas （N2 ＋ C2H2 ＋ NH3） with Al-Mg-Ti melts. The condition for the formation of AlN was that the treatment temperature must be higher than 1373 K, and the amounts of AlN and TiC increased with the increase of the treatment temperature and the gas injection time It was considered that AlN was formed by the direct reaction of Al with nitrogen-containing gas at the interface of the gas bubble and the melt. However, the mechanism of TiC formation is a combination mechanism of solution-precipitation and solid-liquid reaction.     

Fabrication of AlN-TiC/Al composites by gas injection processing

1. Introduction Al-based metal matrix composites (MMCs) with ceramics like SiC, Al2O3, TiC, AlN, TiN, and TiB2 as the reinforcement phase have been widely studied by some researchers. It has been reported that TiC and AlN are particularly attractive because of good wettability and high stability with molten aluminum, high hardness, and elastic modulus [1-4]. To fabricate MMCs, various techniques have been developed. Among these, the in situ technolo- gies are particularly attractive b…     

Modeling of gas phase diffusion transport during chemical vapor infiltration process

1　ＩＮＴＲＯＤＵＣＴＩＯＮＴｈｅｃｈｅｍｉｃａｌｖａｐｏｒｉｎｆｉｌｔｒａｔｉｏｎ (ＣＶＩ)ｍｅｔｈｏｄｉｓｏｎｅｏｆｔｈｅｍｏｓｔｐｒａｃｔｉｃａｌａｎｄ ｐｒｏｍｉｓｉｎｇ ｐｒｏｃｅｓｓｆｏｒｆａｂｒｉｃａｔｉｏｎｏｆｃｅｒａｍｉｃ/ｃａｒｂｏｎｍａｔ     

Study on chaos in short circuit gas metal arc welding process

Based on the chaos theory, an idea is put forward to analyze the short circuit Gas Metal Arc Welding （ GMAW-S） process. The theory of phase space reconstruction and related algorithms such as mutual information and so on, are applied to analyze the chaos of the GMAW-S process. The largest Lyapunov exponents of some current time series are calculated, and the results indicate that chaos exists in the GMAW-S process. The research of the chaos in the GMAW-S process can be help to get new knowledge of the process.     

Influence of melt superheat on breakup process of close-coupled gas atomization

In close-coupled gas atomization（CCGA）, the influences of melt superheat on breakup process are fundamental to obtain desired or finer powder. Based on a series of Cu atomization experiment under different superheating conditions, the influences of melt superheat on breakup process were studied. Experimental results indicate that as the melt superheat is increased to 150, 200, 250 and 300 K, the mean particle size （D50） decreases consequently to 34.9, 32.3, 30.9 and 19.7 μm. Theoretical analysis reveals that the primary breakup and secondary breakup processes are close coupled, and the melt superheat radically influences the melt properties, and plays a crucial role on governing the filming process of primary breakup and the atomization modes of secondary breakup. There exists a strong nonlinear decrease of contact angle of melt to nozzle orifice wall when the superheat is increased fi＇om 250 K to 300 K, leading to a marked fall of the film thickness formed in primary breakup, and D50 of copper powders is therefore sharply reduced. However, the log-normal distribution feature of particle size has not been substantially improved.     

Double-sided gas tungsten arc welding process on TC4 titanium alloy

TC4 titanium alloy was welded by double-sided gas tungsten arc welding（GTAW） process in comparison with conventional GTAW process, the microstructure and mechanical performance of weld were also studied. The results indicate that double-sided GTAW is superior over regular single-sided GTAW on the aspects of increasing penetration, reducing welding deformation and improving welding efficiency. Good weld joint was obtained, which can reach 96.14% tensile strength and 70.85% elongation percentage of the base metal. The grains in heat-affected zone（HAZ） are thin and equiaxed and the degree of grain coarsening increases as one moves to the weld center line, and the interior of grains are α and α′ structures. The coarse columned and equiaxed grains, which interlace martensitic structures α′ and acicular α structures, are observed in weld zone. The fracture mode is ductile fracture.     

Numerical simulation of stress and deformation of in-service welding onto gas pipeline

SYSWELD was used to simulate in-service welding process of gas pipeline of X70 pipeline steel. Welding thermal cycle, stress and deformation of in-service welded joint were studied. The results show that peak temperature of coarse grain heat-affected zone （CGHAZ） of in-service welding onto gas pipeline is the same with routine welding, but ts/5, ts/3 and ts/1 decrease at certain degree. For the zone near welded seam, axial stress and hoop stress in the inner pipe wall are compressive stress when welding source passes through the cross-section that is studied, but residual axial stress and residual hoop stress after welded are all tensile stress. Transient deformation and residual deformation are all convex deformation compared with the original pipe diameter size. Deformation achieves maximum when welding thermal source passes through the cross-section that is studied and then decreases during the cooling process after welding.     

Physical modeling of gas induced bath flow in drained aluminum reduction cell

A room temperature physical model was used to study the bubble behavior and gas induced bath circulation in a drained aluminum reduction cell. By passing compressed argon through the penetrated Plexiglas box bottom plate immersed in water, gas evolution at the anode bottom surface was simulated. Bubble behavior and liquid flow field were studied and analysis was presented. Bath secondary recirculation was observed in the interpolar gap not the net rising flow as expected. Liquid driven by the bubbles forms small vortices along the interpolar gap with small mean and turbulent velocities and accordingly poor mass transfer. Secondary recirculation also exists between the slot and interpolar gap, part of the flow in the interpolar gap go to the slot with the bubbles and fluid at the bottom of the slot enters the interpolar gap directly without going to the center channel. The existence of the fluid secondary recirculation is very unfavorable to the alumina dissolution and dispersion. Increasing the anode tilt or gas flow rate, or decreasing the anode-cathode distance can make the secondary recirculation in the interpolar gap weak, however, will intensify the secondary recirculation between the slot and interpolar gap.     

Pulsed gas metal arc welding of Al–Cu–Li alloy

Abstract

An experimental Al–Cu–Li–Mg–Ag–Zr type alloy in the form of 13.7 mm thick plates was studied for its fusion characteristics using gas metal arc welding (GMAW) and pulsed gas metal arc welding (P-GMAW). High copper 2319 filler of 1.6 mm diameter was used. The burn-off characteristics of 2319 filler wire in GMAW and P-GMAW were experimentally determined, including the relation between pulse current and pulse duration for the desired one-drop detachment per pulse (ODPP) condition and feasible range of pulse parameters. The effect of welding parameters on bead geometry and shape relationships was investigated through beadon-plate experiments in the welding current range above the spray transition current. Reasonably good weld beads were obtained in P-GMAW at currents as low as 194 A and welding speeds of 45 cm min^–1. P-GMAW yielded significantly higher weld penetration compared to GMAW.     

Specular reflection based sensing surface deformation of gas tungsten arc weld pool

A sensing system is developed to measure the weld pool boundary and pool surface deformation in gas tungsten arc welding. LaserStrobe technique is used to eliminate the strong arc light interference, and specular reflection from the pool surface is sensed to describe the relation between the deformed stripes and pool surface depression. Clear images of both the pool boundary and the deformed stripes edges are obtained during gas tungsten arc welding process, which lays foundation for real-time monitoring the pool surface depression and weld penetration.     

A model for the kinetics of mechanically assisted gas–solid reactions

This paper proposes a phenomenological model for the kinetics of mechanically induced gas–solid reactions, based on a thermal analogy and supported by the isokinetic character shown by the absorption curves when the specific energy dose is considered. In addition, the rate constant for mechanically assisted nitriding of IVb metals is found to scale with the milling intensity.     

Mathematical simulation of gas induced bath flow in drained aluminum reduction cell

A mathematical model describing the bubble driven bath flow in a drained cell with a center sump was presented, which spanned the fluid around half an anode and was developed to simulate the flow fields. The calculated results show reasonable agreement with the experiment. Then the model was developed to a full cell model, and bath flow pattern in the whole cell was predicted and analyzed. The flow pattern variation with the changes of the ACD, anode slope, anode immersion depth and current density, especially the fluid secondary recirculation, was modeled. According to the results, side channel or slots feeding technique was recommended in such a drained cell.     

Purification technology of flue gas from remelting process of aluminum alloy tailings

1　ＩＮＴＲＯＤＵＣＴＩＯＮＩｎａｎａｌｕｍｉｎｕｍａｌｌｏｙｃａｓｔｉｎｇｗｏｒｋｓｈｏｐｏｆｔｈｅａｕｔｏｍｏｂｉｌｅｃａｒｂｕｒｅｔｏｒ ｐｌａｎｔ,ｔｈｅｒｅａｒｅｔｅｎｅｌｅｃｔｒｉｃｆｕｒｎａｃｅｓ ,ａｍｏｎｇｗｈｉｃｈｓｉｘｏｐｅｒａｔｅｓｉｍ     

Mathematical model of a heat source in gas‐shielded consumable electrode arc welding

It is shown that a promising technique for pipeline inner surface corrosion prevention is paint-and-lacquer materials and epoxy resin application. Pipe connection techniques are considered. It is established that to form a full-strength welded joint of the double-layer pipes steel 12X18H10T – steel 20 and metal main volume, it is necessary to use electrodes EA 395/9 or a combination of the electrodes ZIO-8 as a root, filling and UONI-13/55 as facing.