Weld process model for simulating metal active gas welding

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Generally, optimum welding variables and conditions of manufacturing are currently mainly determined by experiments for standardized production. Virtual manufacturing and virtual testing of weldments using finite element method provide a sustainable solution for advanced applications. The aim of the current research work is to develop a weld process model, using a three-dimensional heat transfer model, to ensure general applicability for typical joints of stator segments of wind turbines as a final application. A systematic experimental research program, containing temperature measurements during welding, macrographs, and deformation measurements, is carried out on small-scale test specimens using different welding variables. In addition, a numerical study using uncoupled transient thermomechanical analysis is performed. The weld process model uses Goldak’s double ellipsoidal heat source model for a metal active gas welding power source. It describes the correspondence between heat source parameters and net heat input for two types of electrodes. The model is validated via cross-sectional areas of fusion zones and deformations based on experiments. The relationship between current and voltage is determined based on large number of experimental data; thus, selecting a wire type, travel speed, and voltage directly defines the heat source parameters of the weld process model.