Abstract
Electro-chemical discharge micro welding (ECDMW) is a newer potential welding technique that can be effectively employed for micro welding of thin thermocouple wires of two dissimilar metals. The study of temperature distribution in the weld bead formed during ECDMW is important from the quality of weld bead point of view. The high temperature generated in the micro weld bead leads to micro-cracks and thermal residual stresses. Keeping this in view, a finite element method (FEM) based on transient thermal model has been developed assuming the immersed twisted thermocouple wire as semi-infinite uniform cylinder. The obtained results of temperature distribution in welding zone of chromel-alumel thermocouple wire; with consideration of temperature dependent thermal properties and phase change effect are compared with the known experimental results. The effects of wire diameter, applied voltage and type of electrolyte on temperature distribution are reported.
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