Development of Finite Elemental Analysis Model for Numerical Simulation of TIG Welding of Thin Aluminium Sheet

Abstract

AbstractAluminium and aluminium alloy are one of the preferable materials for manufacturing aircraft and automobile components, due to their adequate strength and lightweight. However, it is challenging to weld the aluminium using a conventional arc welding process, due to the formation of aluminium oxide on the surface of the aluminium. TIG welding process is one of the suitable welding processes for welding aluminium alloy. However, TIG welding of aluminium alloy depends on multiple parameters such as voltage, current, and scan speed. The experimental analysis of the welding process is time-consuming and costly. Finite element analysis (FEA) is one of the preferable methods of predicting the welding process and parameters. In this study, the effect of various welding parameters, i.e. voltage, current, and scan speed, on the weld pool formation is analysed using the FEA process. The weld pool thermal behaviours concerning time have been predicted by considering Gaussian heat source utilizing FEA software (ANSYS). The FEA analysis of the welding process showed that melt pool size increases with an increase in welding current and decreases with the increase in scan speed. KeywordsArc weldingNumerical investigationThermal modellingANSYS