A unified numerical modeling of stationary tungsten-inert-gas welding process |
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Authors: | Manabu Tanaka Hidenori Terasaki PhD Masao Ushio John J Lowke |
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Affiliation: | (1) the Joining and Welding Research Institute, Osaka University, 567-0047 Osaka, Japan;(2) the Department of Telecommunications and Industrial Physics, CSIRO, 2070 Lindfield, NSW, Australia |
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Abstract: | In order to clarify the formative mechanism of weld penetration in an arc welding process, the development of a numerical
model of the process is quite useful for understanding quantitative values of the balances of mass, energy, and force in the
welding phenomena because there is still lack of experimentally understanding of the quantitative values of them because of
the existence of complicated interactive phenomena between the arc plasma and the weld pool. The present article is focused
on a stationary tungsten-inert-gas (TIG) welding process for simplification, but the whole region of TIG arc welding, namely,
tungsten cathode, arc plasma, workpiece, and weld pool is treated in a unified numerical model, taking into account the close
interaction between the arc plasma and the weld pool. Calculations in a steady state are made for stationary TIG welding in
an argon atmosphere at a current of 150 A. The anode is assumed to be a stainless steel, SUS304, with its negative temperature
coefficient of surface tension. The two-dimensional distributions of temperature and velocity in the whole region of TIG welding
process are predicted. The weld-penetration geometry is also predicted. Furthermore, quantitative values of the energy balance
for the various plasma and electrode regions are given. The predicted temperatures of the arc plasma and the tungsten-cathode
surface are in good agreement with the experiments. There is also approximate agreement of the weld shape with experiment,
although there is a difference between the calculated and experimental volumes of the weld. The calculated convective flow
in the weld pool is mainly dominated by the drag force of the cathode jet and the Marangoni force as compared with the other
two driving forces, namely, the buoyancy force and the electromagnetic force. |
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