Simulation Of Welding Process Research Articles

Enhancement of joint quality for laser welded dissimilar material cell-to-busbar joints using meta model-based multi-objective optimization

In the battery pack assembly, it is essential to ensure that the cell-to-busbar joints can be produced with high quality and with minimal impact on the individual battery cells. This study examines the influence of process parameters on the joint quality for nickel-plated copper and steel plates, laser welded in an overlap configuration. Artificial neural network-based meta models, trained on numerical results from computational fluid dynamics simulations of the laser welding process, are used to predict and evaluate the joint quality. A set of optimized process parameters is identified, in order to simultaneously maximize the interface width for the joints, and minimize the formation of undercuts and in-process temperatures. In an meta model-based multi-objective optimization approach, the non-dominated sorting genetic algorithm II (NSGA-II) is used to efficiently search for trade-off solutions and the meta models are used for objective approximation. As a result, the objective evaluation time is decreased from around 9 h, when evaluated directly from numerical simulations, to only tenths of a second. From the Pareto-optimal front of trade-off solutions, three optimal solutions are selected for validation. The selected solutions are validated through laser welding experiments and numerical simulations, resulting in joints with large interface widths and low in-process temperatures without a full penetration.

Numerical simulation of a laser beam welding process: From a thermomechanical model to the experimental inspection and validation

In laser beam welding (LBW) complex physical phenomena occur during laser-material interaction, which prolong the parameterisation of the process due to the extended trial and error tests. Therefore, predicting the process behaviour leads to a more productive and cost-reduced process experimental tuning. Besides, as LBW is a thermal process, part distortion plays a relevant role in the final result, and hence, thermal and mechanical analysis are both required. In view of this, in the present research, a novel multiscale numerical model, capable of predicting the thermomechanical behaviour of the LBW process has been developed. The significance of the model is its capability of forecasting the part distortion and thermal field employing two fully coupled modules, where the laser heat source automatically adapts to the welding regime without the need to consider the melt pool dynamics and at a low computational cost. The local model determines the melt pool dimensions and thermal field. Besides, the second module, the global model, figures out the part distortion based on the thermal results. Finally, the presented numerical simulations are experimentally validated with the corresponding temperature monitoring during the welding process, the posterior metallography inspection, and the part deformation measurement. The results present a high accuracy, with a maximum error below 10 % at the temperature measurements, an average dimensional deviation of 0.14 mm and 0.18 mm respectively for the weld bead depth and width, and a vertical deformation average error of 0.15 mm.

Numerical simulation of high-frequency induction welding in longitudinal welded tubes

In the present paper the high-frequency induction welding process is studied numerically. The mathematical model comprises a harmonic vector potential formulation of the Maxwell equations and a quasi-static, convection dominated heat equation coupled through the Joule heat term and nonlinear constitutive relations. Its main novelties are a new analytic approach which permits to compute a spatially varying feed velocity depending on the angle of the Vee-opening and additional spring-back effects. Moreover, a numerical stabilization approach for the finite element discretization allows to consider realistic weld-line speeds and thus a fairly comprehensive three-dimensional simulation of the tube welding process.

Parametric optimisation of laser welding of stainless steel 316L

This paper presents numerical and experimental studies focused on the optimisation of laser welding parameters for AISI 316L stainless steel. The focus of the numerical studies was to obtain the mathematical model with the least time complexity and the highest fidelity. Based on the comparison of different mathematical models, a combination of two models, double ellipsoidal and conical models, was found to be optimal for the numerical simulation of the laser welding process. The studies were also complemented by material characterization studies for validation purpose. A pulse duration of 8 milliseconds and a current of 400 amperes with an average power of 380W were found to be the optimum parameters for laser welding of standard gauge 12 sheet of stainless steel AISI 316L. In addition, the effect of duty factor of the pulsed laser beam on the weld profile was also investigated and was found to be a major contributor to the optimisation process. The properties of the sample welded with the optimised set of parameters were also compared with the base metal, and based on the mechanical characterisation studies, it was found that the yield strength and hardness of the welded sample were improved, but the overall ductility was slightly reduced as compared to the base metal. The average weld zone size was also reduced by increasing the power density due to multiple reflections of the beam.

Effect of Femtosecond‐Laser‐Induced Surface Textures on the Microstructure and Mechanical Properties of Mg/Ti Dissimilar Alloys Laser Lap Welds: A Numerical and Experimental Study

The strength of the joints in the Mg/Ti laser welding is difficult to meet the requirement because of the metallurgical incompatibility. This study investigates the influence of microgroove width on the diffusion of molten Mg and the mechanical properties of joints by laser welding Ti6Al4V and AZ31B, employing femtosecond lasers to fabricate microgrooves on the surface of Ti alloys. The optimal contact angle of 56.4° is achieved at the microgroove width of 100 μm because the leading and trailing edges of the microgroove texture can stimulate the formation of the microriveted structure, facilitating the fluidity of the liquid AZ31B. The joint's tensile–shear capability is increased to 2449.9 N, which is 2.8 times stronger compared to joints without microgroove textures, when using a microgroove width of 100 μm and a laser power of 52%. The numerical simulation of the laser welding process was implemented to analyze the temperature field and the fluid characteristics within the melt pool. In the results, it is shown that the microgroove enhanced the material exchange at the interface and accelerated the interfacial reaction, which stimulates the formation of Ti–Al and Mg–Al intermetallic compounds at the central interface of the joint and enhances the Mg/Ti metallurgical bonding.

Thermomechanical and microstructural simulation of rotary friction welding process of Inconel718 alloy using the finite element method

Thermomechanical and microstructural simulation of rotary friction welding process of Inconel718 alloy using the finite element method

Modeling and simulation of friction stir welding process: A neural approach

Friction Stir Welding (FSW) stands out as a groundbreaking method in solid-state joining for aluminum alloys, presenting an innovative way to achieve joints of exceptional quality. This research delves into the application of FSW for bonding, focusing on plates that are 6mm thick and made from aluminum alloys Al6063, Al5083, and AL6061, aiming to produce a variety of FSW joints. To evaluate the quality of these joints, the study compares mechanical properties such as tensile strength, safe bending strength, and bending toughness necessary for achieving a 90° bend. The investigation leverages welding data to formulate a neural model, starting with using a conventional feedforward neural model (CFNM). It tackles the limitations of CFNM, including its intensive training requirements and the challenge of dealing with unknown configurations, by proposing a new, more adaptable neural network model known as FNNM. When comparing the two models, it becomes evident that CFNM is constrained by a root mean square error (RMSE) of 7-15%, whereas FNNM marks a significant improvement with a minimal RMSE of 1-3%. This indicates that FNNM improves accuracy and effectively navigates the complexities of modeling with unknown parameters. Through this study, insightful contributions are made to understanding FSW in joining aluminum alloys and developing an advanced neural model capable of predicting the outcomes of welding with greater precision.

Thermal-Mechanical and Microstructural Simulation of Rotary Friction Welding Processes by Using Finite Element Method.

Rotary friction welding is one of the most crucial techniques for joining different parts in advanced industries. Experimentally measuring the history of thermomechanical and microstructural parameters of this process can be a significant challenge and incurs high costs. To address these challenges, the finite element method was used to simulate thermomechanical and microstructural aspects of the welding of identical superalloy Inconel 718 tubes. Numerical simulation results were used to compute essential mechanical and metallurgical parameters such as temperature, strain, strain rate, volume fraction of dynamic recrystallization, and grain size distribution. These parameters were subsequently verified using experimental test results. The Johnson-Avrami model was utilized in the microstructural simulation to convert thermomechanical parameters into metallurgical factors, employing a FORTRAN subroutine. The calculated thickness of the recrystallization zone in the wall was 480 and 850 μm at the tube wall's center and edge, respectively. These values were reported from experimental measurements as 500 and 800 μm, respectively. The predicted grain size changes from the center to the edge of the wall thickness, near the weld interface, ranged from 2.07 to 2.15 μm, comparable to the experimental measurements ranging from 1.9 to 2.2 μm. Various curves are also presented to explore the correlation between thermomechanical and microstructural parameters, with the experimental results revealing predictable microstructure evolutions correlated with thermomechanical changes.

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.

Distribution and Characteristics of Residual Stresses in Super Duplex Stainless Steel Pipe Weld

This paper explores the distribution and features of residual stresses formed by super duplex stainless steel pipe welding. Experimental investigations, which encompass an elevated temperature tensile test and metallographic observation along with a hardness test and residual stress measurement, were first conducted to obtain the mechanical properties at high base metal temperatures and to confirm whether or not the duplex stainless steel undergoes martensitic phase development during the welding process. Finally, experiments were performed to scrutinize the residual stress evolution through the metallurgical phase transformation in the weld region and its vicinity. A sequentially coupled 3D thermal, mechanical and metallurgical finite element (FE) model capable of incorporating the experimental consequences was established next. A 3D FE simulation of the girth welding process was conducted, and the axial and hoop residual stress profiles along the girth were evaluated. The results substantiate that martensitic phase evolution occurs in the process of cooling during the welding of super duplex stainless steel, and they also highlight the significance of taking the metallurgical phase transformation into account in the numerical reproduction of the girth welding process for the accurate expression of weld-induced residual stresses, which is especially important for precisely predicting hoop residual stresses.

Study on copper-stainless steel explosive welding for nuclear fusion by generalized interpolated material point method and experiments

The thick copper stainless steel composite plate is an important component of the cooling coil terminal box of international nuclear fusion reactors. The composite rate, tensile strength, shear strength, and interface waveform of the metal plate are also far higher than the requirements of conventional explosive welding technology. It is difficult to obtain the best technical process parameters in a short time solely relying on conventional explosive welding tests. In order to solve the above-mentioned technical difficulties in explosive welding, this article applies the generalized interpolation material point method (GIMP) based on the explosive welding window, metal elastic-plastic mechanics, and explosive detonation theory to conduct macroscopic three-dimensional and microscopic two-dimensional numerical simulations of the copper stainless steel explosive welding process and the composite interface wave formation process, respectively. The experimental results demonstrate that the GIMP has significant advantages in numerical calculation and analysis for the explosive welding problem of high-speed impact collision of metal plates driven by explosive detonation, and it can effectively solve the technical problems of high technical specifications, low explosive processing composite rate, and low interface strength of large thickness copper stainless steel composite plates used in nuclear fusion.

Current Status and Future Prospects of Numerical Simulation of Arc Welding Process

Current Status and Future Prospects of Numerical Simulation of Arc Welding Process

A Selective Integration-Based Adaptive Mesh Refinement Approach for Accurate and Efficient Welding Process Simulation

To save computational time and physical memory in welding thermo-mechanical analysis, an accurate adaptive mesh refinement (AMR) method was proposed based on the feature of moving heat source during the welding. The locally refined mesh was generated automatically according to the position of the heat source to solve the displacement field. A background mesh, without forming a global matrix, was designed to maintain the accuracy of stress and strain after mesh coarsening. The solutions are always carried out on the refined computational mesh using a selective integration scheme. To evaluate the performance of the developed method, a fillet welding joint was first analyzed via validation of the accuracy of conventional FEM by experiment. Secondly, a larger fillet joint and its variations with a greater number of degrees of freedom were analyzed via conventional FEM and current AMR. The simulation results confirmed that the proposed method is accurate and efficient. An improvement in computational efficiency by 7 times was obtained, and memory saving is about 63% for large-scale models.

Effect of different friction coefficient models on numerical simulation of inertia friction welding of 2219 Al alloy to 304 stainless steel

In inertia friction welding (IFW) of Al alloy to steel, the friction coefficient of interface influences the friction heat production and determines the accuracy of the numerical simulation of welding process. A fully coupled three-dimensional model was established to simulate the IFW process of 2219 Al alloy to 304 stainless steel. By taking different simplifications in the influencing factors (i.e., temperature, sliding velocity, and pressure) of friction coefficient, three types of friction coefficient models were established and utilized in the simulation of IFW process. The strain compensated Arrhenius and Johnson-Cook models were employed to describe the deformation behavior of Al alloy and steel, respectively. Both Al alloy and steel were assumed to be the elastic-plastic body, and the friction stress was calculated by the Coulomb friction model. The friction interface temperature, angular velocity attenuation, axial shortening distance, and joint appearance were measured to verify and compare the accuracy of the established models. The temperature and stress evolutions during the IFW process were also analyzed. With the smallest error in validation, the friction coefficient model, which was a function of temperature, sliding rate, and pressure, showed the best accuracy in describing the friction behavior. By considering the effect of pressure, a more accurate shear stress at the center region of the interface was calculated with a lower value. It means that the friction resistance at the region was lower, promoting the flow of internal Al alloy and the formation of curly-shape flash.

Challenges in dynamic heat source modeling in high-power laser beam welding

The amount of absorbed energy in the keyhole as well as its spatial and temporal distribution is essential to model the laser beam welding process. The recoil pressure, which develops because of the evaporation process induced by the absorbed laser energy at the keyhole wall, is a key determining factor for the macroscopic flow of the molten metal in the weld pool during high-power laser beam welding. Consequently, a realistic implementation of the effect of laser radiation on the weld metal is crucial to obtain reliable and accurate simulation results. In this paper, we discuss manyfold different improvements on the laser-material interaction, namely, the ray tracing method, in the numerical simulation of the laser beam welding process. The first improvement relates to locating the exact reflection points in the ray tracing method using a so-called cosine condition in the determination algorithm for the intersection of reflected rays and the keyhole surface. A second correction refers to the numerical treatment of the Gaussian distribution of the laser beam, whose beam width is defined by a decay of the laser intensity by a factor of 1/e2, thus ignoring around 14% of the total laser beam energy. In the third step, the changes in the laser radiation distribution in the vertical direction were adapted by using different approximations for the converging and the diverging regions of the laser beam, thus mimicking the beam caustic. Finally, a virtual mesh refinement was adopted in the ray tracing routine. The obtained numerical results were validated with experimental measurements.

Research on AZ31 Mg alloy/22MnB5 steel pinless friction stir spot welding process and interfacial temperature field simulation

This paper discusses the successful welding of AZ31 Mg alloy to 22MnB5 high-strength steel using pinless friction stir welding (P-FSSW) to join dissimilar metals and reduce vehicle weight while maintaining strength and stiffness. P-FSSW eliminates fusion welding defects, ensuring good performance of Mg/steel welds. An orthogonal experimental design was adopted to comprehensively analyze welding parameters for determining the optimum P-FSSW process conditions. The study provides an in-depth examination of the interfacial layer formation between AZ31 Mg alloy and 22MnB5 steel, emphasizing the importance of Al for effective bonding in Mg alloys. Numerical simulation of the welding process's temperature field is verified by thermocouple measurements, confirming result accuracy. The study aims to optimize bonding of dissimilar materials and facilitate interfacial reactions for achieving high-performance welded joints. This comprehensive understanding of the P-FSSW process and interfacial layer formation holds great significance for lightweight construction in the automotive industry, contributing to reduced emissions and improved fuel efficiency.

Numerical analysis of coupling dynamics of keyhole and molten pool in vertical-up laser mirror welding of 2219 aluminum alloy

In vertical-up laser mirror welding, the keyhole dynamics and flow behavior of molten pool play crucial roles in weld quality, yet the mechanisms of these coupling dynamics have not been well clarified. In this work, a three-dimensional transient model for simulation of vertical-up laser mirror welding process was carried out to account for the flow behavior of molten pool and dynamic evolution characteristics of keyhole. Two laser heat sources with regard to laser mirror welding were also taken into consideration in the combined heat source model. It is proved that the simulation results are basically consistent with the experimental data. The simulation results indicate that the morphology and flow field distribution of upper and lower molten pool both exhibit a high degree of consistency on the X–Y section, while significant difference is visible on the X-Z section. Before keyhole coupling, the high velocity fluid exists on the surface of molten pool and tends to increase the diameter of keyhole, of which the maximum velocity reaches 5.26 m s−1. During the keyhole coupling process, the coupled keyhole in the center area is found to fall, which results in deteriorated coupling process. Force analysis of keyhole illustrates that the resultant force on the X–Y section points to the direction of increasing the depth and diameter of keyhole before and during the keyhole coupling process. In contrast, the resultant force on the X-Z section is conductive to keyhole coupling occurring at the lower position. After keyhole coupling, the diameter of coupled keyhole in the center zone is increased and the fluid velocity is reduced to 0.109 m s−1, contributing to a firm connection.

Optimization of the Pressure Resistance Welding Process for Nuclear Fuel Cladding Coupling Experimental and Numerical Approaches

An approach coupling experimental tests and numerical simulation of the pressure resistance welding (PRW) process is proposed for optimizing fuel cladding welds for the new generation of nuclear reactors. Several experimental welds were prepared by varying the dissipated energy, which accounts for the effect of electric current and welding time applied during the PRW process. A working zone, a function of both applied dissipated weld energy and plug-displacement, was then identified on the basis of the microscopy observations of the weld defects. In addition, the numerical approach, based on a 2D axisymmetric multi-physics finite element model, was developed to simulate the PRW process in a plug-tube configuration. The proposed model accounted for interactions between the electrical, thermal and mechanical phenomena and the electro-thermo-mechanical contact between the pieces and electrodes. Numerical simulations were first validated by comparison to experimental measurements, notably by comparing the plug-displacement and the size and position of the heat-affected zone (HAZ). They were then used to assess the effect of the applied parameters on the maximum temperature and cumulated plastic strain reached during welding and the effect of the welding force on the quality of the weld. According to the numerical computations, the maximum temperature reached in the weld remains well below the melting temperature. Changing the welding force implies also modifying the applied energy in order to maintain the quality of the welds. Applied to different plug and clad geometries, the proposed model was shown to be useful for optimizing the joint plane for such a welding configuration.

Effect of plate placement on nugget shape in joining dissimilar thickness automotive steel thin sheets using resistance spot welding

The automotive products are adopting modern design dynamics to meet the market demands. One of the challenges that the automotive industries are facing is joining dissimilar thickness steel panels. The current study is an attempt to understand the formation of nugget shape during the resistance spot welding process in joining dissimilar thickness automotive steel AISI 4340. Steel plates with two different thickness of 2 mm and 1.5 mm are considered in the current investigation. The numerical simulation of the resistance spot welding process is carried out in FEM based commercially available software package. The study revealed that the temperature and the shape of the nugget is not same with the alteration of the positioning of the steel plates having dissimilar thickness. The shapes of the nuggets are different when the plate with higher thickness is at the top than the nugget formed when the plate is placed at the bottom.

Design of welding parameters for laser welding of thick-walled structures made of aluminum alloy

The paper deals with the laser welding of thick-walled plates with a thickness of 20 mm made of EN AW5083-H111 aluminum alloy. A simulation model for the analysis of the laser welding process is developed and verify using temperature measurement during experimental laser welding of samples by a TruDisk 4002 laser device. Based on the numerical simulation of the laser welding process in the ANSYS program code, suitable parameters for production of high-quality weld joints were suggested. For welding at a speed of 10 mm.s−1, the laser power of 7 kW is recommended. A laser with the power of 10 kW is required for the higher welding speed of 20 mm.s−1.