Heat Source Model Research Articles

Heat source models for numerical simulation of laser welding processes – a short review

In recent decades, numerical modeling and computer simulation have become an integral part of the design, analysis and optimization of fusion welding processes, including laser welding. In general, laser welding processes involve the interaction of multiple physical phenomena, such as thermal, fluid, metallurgical, chemical, mechanical, and diffusion effects, which makes the development of a simulation model difficult and complex. In addition to the geometric characteristics of the parts to be welded, their material properties must be specified in a wide temperature range, as well as the conditions for heat removal to the environment or shielding gas. One of the most complex tasks in the preparation of a simulation model of the laser welding processes consists in the selection of an appropriate heat source model to accurately determine the heat input to the weld. Very important is also the process of experimental verification and validation of the developed simulation models. In this paper, a short examination of significant mathematical heat source models for numerical simulation of laser welding is provided. Numerical analysis of laser welding of sheets made of S650MC steel is accomplished using conical 3D heat source model with the support of the ANSYS code. The effect of geometrical characteristics of the conical volumetric heat source model on the computed width, length, and depth of the weld pool is discussed, along with evaluation of maximum weld pool temperature.

Temperature Field Simulation and Experimental Confirmation of Laser Cladding High-Entropy Alloy Coating on Cr12MoV

In order to meet the mechanical property of the die steel, this study used laser cladding to prepare a high-entropy alloy coating on Cr12MoV. A finite element method using a double ellipsoidal heat source model is proposed to simulate the evolution of the temperature field in laser cladding. The simulation results showed that with the increase in the power, the peak temperature of the molten pool increased from 2005.5 °C to 2357.4 °C, and the depth of the molten pool increased from 1.60 mm to 2.04 mm. The coating with the laser power of 1600 W had a good macroscopic quality and high lattice distortion (2.43 × 10−2). Due to the increase in laser energy density, the size of equiaxed crystals gradually increased from 1400 W to 1700 W. Under the comprehensive effect of the solution and fine grain strengthening, the coating with the power of 1600 W had a higher average microhardness (600 HV), which is 150% higher than that of the substrate. The experiment results further confirmed the accuracy of the simulation.

Effect of Residual Stress on the Ultimate Bearing Capacity of Titanium Alloy Pressure Spherical–Cylindrical-Combined Shells

Titanium alloy pressure spherical–cylindrical shells enable the effective utilization of the strength of spherical and cylindrical pressure-resistant shell components. In this study, a numerical simulation of the residual stress of a titanium alloy butt-welding plate was conducted by employing sequential coupling and a temperature heat source model. The results of welding residual stress analysis agreed well with the experimental results reported in the literature. Subsequently, the welding residual stress of a titanium alloy pressure spherical–cylindrical shell was calculated and analyzed using the same method. Finally, the influence of residual stress on the ultimate bearing capacity of the shell was assessed. On the inner surface of the shell, the horizontal welding residual tensile stress, perpendicular to the weld path, exhibited a bimodal distribution. The longitudinal welding residual tensile stresses were higher than the horizontal welding residual stress. Near the weld on the outer shell surface, higher longitudinal welding residual tensile stresses existed, whereas the horizontal welding residual stress was compressive. Both the inner and outer shell surfaces exhibited significant longitudinal residual tensile stresses along the weld path, though residual compressive stresses existed on both surfaces. The influence of welding residual stress on the ultimate load-bearing capacity of the shell was minimal.

Heat Source Model Development for Thermal Analysis of Laser Powder Bed Fusion Using Bayesian Optimization and Machine Learning

To understand the correlation between process, structures, and properties in laser powder bed fusion (L-PBF), it is essential to use numerical analysis as well as experimental approaches. A finite element thermal analysis uses a moving heat source model represented as a volumetric heat flux to simulate heat input by laser. Because of its computational efficiency, finite element thermal analysis is suitable for iterative procedures such as parametric study and process optimization. However, to obtain valid simulated results, the heat source model must be calibrated by comparison with experimental results for each laser scanning condition. The need for re-calibration limits the applicable window of laser scanning conditions in the thermal analysis. Thus, the current study developed a novel heat source model that is valid and precise under any laser scanning condition within a wide process window. As a secondary objective in the development, we quantitatively evaluated and compared the four heat source models proposed to date. It was found that the most suitable heat source model for the L-PBF is conical one among them. Then, a multiple linear regression analysis was performed to represent the heat source model as a function of laser power and scanning velocity. Consequently, the thermal analysis with the novel model is valid and precise within the wide process window of L-PBF.

A heat source model for dissimilar Al/Cu friction stir welding process based on tool torque measurement

A heat source model for dissimilar Al/Cu friction stir welding process based on tool torque measurement

Optimization‐improved thermal–mechanical simulation of welding residual stresses in welded connections

AbstractThis paper presents a novel computer‐aided computational framework to determine the optimum shape parameters in a welding heat source model using a coupled supervised Gaussian process regression (GPR) and genetic algorithm (GA) approach in estimating the welding residual stresses. The experimental X‐ray diffraction (XRD) approach validates the optimization‐improved thermal–mechanical simulation method. The validation of the proposed approach includes the welded plates with simple geometry to welded pipe‐to‐plate and the circular hollow section joints with complex topologies. The optimization‐derived shape parameters in a welding heat source model lead to close estimates of the temperature history and the welding residual stresses for these types of welded joints considered in this study.

Experimental and numerical investigation of a gouging heat source model and gouging/welding residual stress and deformation

Gouging is generally used for groove preparation of multi-pass welding and repair welding. Arc gouging is one of the most efficient gouging methods which utilizes an arc heat source and a trailing air blower. To date, the heat effects from the arc gouging are not clear especially when it is coupled with subsequent welding. In this study, a new heat source model considering the blown molten metal as well as the increased heat transfer by the blowing air was proposed. A 3D finite element model for gouging and welding was employed to analyze the thermal behavior, welding distortion and residual stresses. The transient temperature predicted by the proposed heat source model has good agreement with thermocouple measurements, both featuring multiple peaks in the thermal profile. The predicted distortion and residual stress due to gouging show similar trends as those in experiment. The proposed analysis approach can provide necessary insights, with high accuracy, in the evaluation of welding distortion and residual stresses in practical manufacturing.

Numerical simulation of temperature field around buried pipes of ground source heat pumps based on mathematical models

The author established a physical and mathematical model for the heat exchange of a ground source heat pump buried heat exchanger under the co-operation of heat and seepage, including the soil and fluid inside the pipe surrounding the heat exchanger. Using ANSYS finite element APDL language for programming, based on the line heat source model, simulate the temperature field around the vertical double U-tube underground heat exchanger, the effects of soil thermophysical properties, temperature outside the pipe, soil type and backfill material on soil temperature field were obtained through simulation analysis. The experimental results indicate that, the changes in soil temperature are also significant with different backfill materials. Therefore, it is necessary to conduct serious research and optimization on backfill materials, develop new types of backfill materials, improve backfill construction techniques, and conduct in-depth research by combining theoretical analysis with practical engineering to ultimately find efficient and economical backfill materials. The change in equivalent pipe diameter has little effect on soil temperature, and the linear heat source model is used for calculation without causing significant errors. It has been proven that the soil itself has strong resilience and has reference value for the design of buried heat exchangers in practical engineering.

A step-by-step thermo-elastoplastic analysis of laser beam welding

In recent years, laser beam welding has emerged as a significant contact-free fusion method due to its advantages such as high laser advance speed and minimal thermal distortion. Automation further increases its attractiveness in various industries. However, specific conditions related to temperature gradient, chemical composition, welding speed and mechanical boundary conditions can lead to solidification cracks. These cracks originate from microcracks within the weld and occur during solidification. The mushy zone is particularly prone to solidification cracking due to the dendritic morphology and entrapped liquid phases. To address this problem, this study makes a step-by-step approach using finite element simulations on the macro- and microscale. It first locates the mushy zone macroscopically using a heat source model and then analyzes the evolving dendritic microstructure at the microscopic level in a simplified manner, considering thermal and elastoplastic effects. This enables a more thorough understanding of the critical states at micro- and macroscale which may lead to solidification cracking.

Numerical Modeling of Distortions and Residual Stresses During Wire Arc Additive Manufacturing of an ER 5183 Alloy with Weaving Deposition

This study deals with the numerical modelling of residual stresses and distortions occurring during wire arc additive manufacturing of ER 5183 parts with weaving deposition. It is shown that the mesh size, as well as the accurate implementation of the heat source weaving pattern has a significant impact on the results. The mechanical material properties for the simulation are evaluated utilizing in-house standardized test equipment. Validation of the thermo-mechanical simulation is done by monitoring temperatures and distortions during the process. Additionally, 3D scans of the part geometry and residual stress measurements using the hole drilling method are conducted post manufacturing. A good agreement between the experimental measurements and the numerical simulation results is found with the use of an accurate heat source model.

Modeling and measurements of temperature field in the arc welding and hybrid plasma-MAG welding heat source models

Modeling and measurements of temperature field in the arc welding and hybrid plasma-MAG welding heat source models

The W-tube energy pile heat transfer model with variable heat flow considering heat exchange between pile and circulating water

In order to provide a more comprehensive depiction of the actual heat transfer process in energy piles, this research paper presents an approximate solution for a finite line heat source model operating under variable heat flow conditions. This solution is established by integrating the finite line heat source model and the superposition principle. Furthermore, the W-tube heat exchanger is divided into many segments, and a segmented superposition approach is used based on the thermal response. Consequently, a heat transfer model for a single-pile heat source is formulated, taking into consideration the heat exchange between the circulating water and the energy pile. Notably, the soil temperature predicted by this proposed model closely aligns with the results obtained from the FLUENT numerical model, thereby substantiating the accuracy of the proposed approach. Simultaneously, the heat transfer model is employed to analyze variations in temperature and heat flux density within the heat exchanger and to investigate the influence of parameters such as mass-flow rate, pile-soil heat transfer coefficient, pile-soil density, and pile-soil specific heat capacity on the heat transfer characteristics of energy piles. This model enables the determination of time-varying heat flux and precise outlet temperature, thereby facilitating a rapid assessment of the heat transfer efficiency of energy piles.

Three-dimensional transient heat transfer analysis of micro-plasma arc welding process using volumetric heat source models

Abstract The micro plasma arc welding process is associated with different physical phenomena simultaneously. This results in complexities to comprehend the actual mechanism involved during the process. Therefore, a robust numerical model that can compute the weld pool shape, temperature distribution, and thermal history needs to be addressed. Unlike, other arc welding processes, the micro plasma arc welding process utilizes thin sheets of thickness between 0.5 and 2 mm. However, joining thin sheets using a high-density arc welding process quickens the welding defects such as burn-through, thermal stresses, and welding-induced distortions. The incorporation of a surface heat source model for computational modeling of the high energy density welding process impedes heat transfer analysis. In that respect, researchers have developed numerous volumetric heat source models to examine the welding process holistically. Although, selecting volumetric heat source models for miniature welding is a significant task. The present work emphasis developing a rigorous yet efficient model to evaluate weld pool shape, temperature distribution, and thermal history of plasma arc welded Ti6Al4V sheets. The computational modeling is performed using a commercially available COMSOL Multiphysics 5.4 package with a finite element approach. Two different prominent thermal models, namely, Parabolic Gaussian and Conical power energy distribution models are used. A comparative analysis is carried out to determine the most suitable heat source model for evaluating temperature distribution, peak temperature, and thermal history. The analysis is done by juxtaposing the simulated half-cross-section weld macrographs with the published experimental results from independent literature. The numerical results showed that the proximity of top bead width magnitude was obtained using the Parabolic Gaussian heat source model for low heat input magnitude of 47.52 and high heat input magnitude of 65.47 J·mm−1, respectively. In terms of percentage error, the maximum top bead width percentage error for the Parabolic heat source model is 13.26%. However, the maximum top bead width percentage error for the Conical heat source model is 18.36%. Likewise, the maximum bottom bead width percentage error for the Parabolic heat source model and the Conical heat source model is 12.3 and 25.8%, respectively. Overall, it was observed that the Parabolic heat source model produces the least deviating outcomes when compared with the Conical distribution. It was assessed that the Parabolic Gaussian heat source model can be a viable heat source model for numerically evaluating micro-plasma arc welded Ti6Al4V alloy of thin sheets.

Material flow and heat transfer characteristics in flat-top laser composite arc-based directed energy deposition

In this study, a novel flat-top laser composite arc-based directed energy deposition process is proposed, and the material flow and heat transfer behaviors are investigated for both arc-only and hybrid flat-top laser modes. Transient CFD models are developed to simulate the energy of the laser and arc using the surface heat source and double-ellipsoid body heat source models, respectively, and validated through experimentation. The results show that the high-temperature metal fluid flows outward from the center of the molten pool and then backward in the front part. The flat-top laser does not alter the flow field pattern but allows for the spread of more hot liquid metal towards the lateral edges. Furthermore, it is discovered that the flat-top laser reduces the contact angle and promotes a stable molten pool temperature.

Non-axisymmetric Modeling of a Moving Heat Source for Thermal Stress and Fatigue Analysis of Railway Vehicle Disc Brakes

Railroad vehicles require the use of disc brakes for safety purposes, however, the brakes are susceptible to thermal stress, which ultimately shortens their lifespan. Hence, to accurately predict the life of railway disc brakes in thermal load simulations, the availability of a model that considers spatial and temporal variations of temperature and thermal stress is essential. A non-axisymmetric moving heat source model was successfully developed to address spatial temperature variations (Deressa and Ambie in Urban Rail Transit 8(3–4):198–216, 2022. 10.1007/s40864-022-00176-9), and this study aims to extend this model to predict thermal stress and fatigue life, and assess its effectiveness. The analysis includes braking time thermal analysis, cooling time thermal analysis, and structural analysis. Spatially varying temperature is incorporated into the structural analysis to calculate thermal stress and strain. A fracture mechanics-based fatigue life estimation method is applied to critical areas of the friction surface. The model is implemented on two braking conditions (service and emergency) and two disc geometries (actual and modified). The model successfully resolves spatial heat considerations by estimating maximum stress variations of up to 46 MPa along the disc circumference. Stress differences of 3 MPa and 6 MPa are observed between the leading and trailing edges of the pad trace during late and mid-braking times, respectively. Fatigue life results identify critical positions and directions for fatigue life initiation. Additionally, these results are in accord with previous observations available in the literature. The proposed model can be easily implemented in various sliding friction applications such as drum brakes, engine pistons/cylinders, and camshafts.

Influence of Initial Structural Dimensions of Plates on Welding Distortion

Aiming at the complex full-field deformation problem that easily occurs when welding plates, this paper adopts the elastic–plastic finite element method with heat-force coupling to study the deformation law of plates in different initial states. First, a rectangular plate finite element model with an initial radius and Gaussian heat source model was established to obtain the welding temperature field and deformation field of the plate; then, the method based on digital image correlation technology was used to detect the full-field dynamic deformation of the plate to verify the accuracy of the finite element model; finally, the influence of the initial structural dimensions of the plate on the weld deformation was investigated. The study shows the following: the thermoelastic–plastic finite element model proposed in this paper has high accuracy in both static and dynamic deformation; plates with the same curvature, and different lengths and widths of the initial structure of the plate welding deformation are saddle-shaped, and the edge effect of the welding of the plate is evident, independent of the length of the plate; and the maximum out-of-face deformation of the welding of the plate is linearly related to the length and the closer the aspect ratio of the plate is to 1, the smaller the out-of-face deformation is.

Evolutions of temperature field and stress field in narrow gap oscillating laser welding process based on equivalent heat source

With the increased demand for high-performance thick high-strength steel structures in high-end offshore equipment, narrow gap oscillating laser welding with the advantage of high power density and satisfied penetration depth has attracted considerable attention. A thermal-elastic-plastic finite element model was established to calculate the narrow gap oscillating laser welding process of 30-mm-thick high-strength steel, which requires a large amount of computational time cost. To increase the computational efficiency, two equivalent heat source models were founded to replace the laser oscillation. The temperature field and stress-strain field were analyzed. The accuracy of the equivalent heat source model was verified from the weld seam profile and residual stress distribution curves. Results showed that the simulated results were in good agreement with the actual results. With the number of welding passes increasing, the cross-section shape of the molten pool changed from an elongated shape to an arc shape, and the groove gap on the top surface was reduced from 4.82 mm before welding to 3.18 mm after welding. The maximum equivalent residual stress, with the value of 669 MPa, was distributed in the middle and upper parts of the weld seam as well as the root. The longitudinal residual stresses exhibited tensile stresses in the weld seam zone. Due to the upward bending of the workpiece, the transverse residual stresses showed compressive stresses on the top surface of the weld seam and maximum tensile stresses with the value of 806 MPa at the bottom of the weld seam.

Optimization of Butt-joint laser welding parameters for elimination of angular distortion using High-fidelity simulations and Machine learning

The high temperature gradient and high cooling rate induced in the butt-joint laser welding process generate a high residual stress, which can result in significant distortion of the final weld. Previous researches usually employed experimental approach to search for optimal parameters which is costly and time consuming. Additionally, there was several studies that used simulation to compute the distortion and to find optimal parameters, however, these studies neglect the effect of solid cooling rate and size of the heat-affected zone (HAZ) in the process of finding optimal parameters. Accordingly, the present study proposes a new systematic framework based on finite element (FE) simulations, regression analysis, and two artificial neural networks (ANNs) for determining the laser welding parameters (i.e., the laser power and welding speed) which minimize the angular distortion of the laser-welded butt joint and enhance the mechanical properties. In the proposed approach, to determine the variables of the selected double-conical heat source model for any combination of the laser power and welding speed is studied within the feasible design space. The variables are then imported into a three-dimensional COMSOL Multiphysics FE model to predict the melt pool dimensions, solid cooling rate, and size of the HAZ as a function of the laser power and welding speed. Finally, the processing map produced by the ANN is screened by four quality criteria based on the melt pool depth, angular distortion, cooling rate, and HAZ width, respectively, to determine the optimal laser welding parameters which minimize the angular distortion and maximize the mechanical properties. It shows that SS316L tensile test specimens fabricated using the optimal parameters have a tensile strength (662 MPa) which is higher than that of the base metal (660 MPa). Furthermore, the angular distortion of the butt-joint samples is less than 564 µm. Thus, the effectiveness of the proposed optimization procedure is confirmed.

Analysis of the sequentially coupled thermal–mechanical and cladding geometry of a Ni60A-25 %WC laser cladding composite coating

In this research, a three-dimensional (3D) transient finite element model based on a sequentially coupled thermal–mechanical analysis (SCTMA) is proposed to simulate the evolution of the temperature field and stress field as well as the cladding geometry of the Ni60A-25 % WC laser cladding composite coating. Based on the thermo-physical properties of Ni60A-25 % WC powder and the design of the double ellipsoidal heat source model, a 3D finite element model of double-layer laser cladding with two channels is established. The evolution of the temperature field and the residual stress field at different laser process parameters are investigated to evaluate the quality of the cladding layer. The impact of different laser cladding process parameters on the cladding dimensions is investigated. The dimensions of the simulated molten pool are analyzed by fitting a polynomial curve. The simulation results show that the laser power is proportional to the temperature, and the temperature growth rate of the coating is significantly higher than that of the substrate. The scanning speed is inversely proportional to the temperature. The maximum temperature of the cladding is 1.5 times the maximum temperature of the substrate. The temperature growth rate of the cladding layer is twice that of the substrate. Due to the asymmetry of the heat source in the multi-pass cladding process, the laser energy absorption rate is not the same on both sides of the melted layer. The double ellipsoidal heat source model has a larger diffusion range in the un-melted powder, resulting in asymmetry in the width direction of the cladding layer. The analysis of the residual stresses in the cladding layer shows that the residual compressive stresses in all paths increase with the increasing laser power. The normal x residual compressive stress in the coating and the maximum residual compressive stress occur at the end of the laser beam scan. The residual compressive stress in all paths decreases as the scanning speed increases. The results show that the dimensions of the molten pool are proportional to the laser power and inversely proportional to the scanning speed. The cladding geometry can be calculated with polynomial fitting equations at a selected laser power (500 W–2800 W) and scanning speed (1 mm/s–8 mm/s). The error analysis of the simulation and the experimental results can validate the proposed finite element simulation model. The error in the molten pool size is less than 20 % for the simulation and experimental results.

Study on configurational operation strategy of ground heat exchangers under the effect of groundwater flow

In large-scale ground source heat pump (GSHP) systems, the accumulation of thermal energy resulting from seasonal load imbalances has emerged as a significant impediment. The implementation of a rational operation strategy can effectively mitigate heat accumulation in soil. This study investigates the impact of the configurational operation strategy for large-scale vertical ground heat exchanger (GHE) on the spatial distribution of ground temperature under the influence of groundwater flow. The internal heat source model is proposed to describe heat transfer process of GHE. Sandbox experiment is conducted to verify the model with maximum deviation of 3 %. The validated model is then utilized to simulate soil temperature profile in the large-scale GHE field over a 10-year operational period, considering a matrix of three configuration strategies and three operation strategies. The results shows that trapezoidal configurations combined with operation Strategy 3 has a minimal temperature increment of 2.9 °C in soil temperature. The contribution of this study lies in provision of a methodology for mitigating thermal accumulation in large-scale GHE field.