Numerical simulation of molten pool behavior and bead formation in Al-alloy GMAW bead-on-plate welding

IF 2.4 4区材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING

Welding in the World Pub Date : 2024-03-28 DOI:10.1007/s40194-024-01754-0

Yinghao Li, Ran Zong, Yujiao Zhang, Boyang Zhang

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Abstract

A transient 3D numerical model was established to investigate the multi-coupling transport phenomena in the Al-alloy GMAW bead-on-plate welding process. An integrated self-adaptive distribution mode of “arc current density-arc pressure-electromagnetic force-arc heat” was proposed to adapt to the evolution of the surface morphology of the molten pool. The heat and force state of the molten pool was analyzed to investigate its influence on the bead formation. The results showed that the arc pressure and droplet impingement promoted the backward flow of the liquid metal, thus forming the gouging region. It decreased the concentration of the arc current density, thereby reducing the superheat of the liquid metal and facilitating the filling of the weld toe. Based on the characteristics of the temperature and velocity fields, the characteristics of weld formation in the three stages of arc preheating, melting, and solidification were analyzed. This study revealed the relationship between molten pool behavior and bead formation, promoting the implementation of Al-alloy GMAW in welding and additive manufacturing.

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铝合金 GMAW 板上焊缝熔池行为和焊珠形成的数值模拟

建立了瞬态三维数值模型，研究了铝合金GMAW珠焊过程中的多耦合输运现象。提出了 "电弧电流密度-电弧压力-电磁力-电弧热量 "的综合自适应分布模式，以适应熔池表面形态的演变。分析了熔池的受热和受力状态，以研究其对熔珠形成的影响。结果表明，电弧压力和液滴撞击促进了液态金属的逆向流动，从而形成了刨削区域。它降低了电弧电流密度的浓度，从而降低了液态金属的过热度，有利于焊趾的填充。根据温度场和速度场的特征，分析了电弧预热、熔化和凝固三个阶段的焊缝形成特征。该研究揭示了熔池行为与焊珠形成之间的关系，促进了铝合金 GMAW 在焊接和增材制造中的应用。

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来源期刊

Welding in the World METALLURGY & METALLURGICAL ENGINEERING-

CiteScore

4.20

自引率

14.30%

发文量

181

审稿时长

6-12 weeks

期刊介绍： The journal Welding in the World publishes authoritative papers on every aspect of materials joining, including welding, brazing, soldering, cutting, thermal spraying and allied joining and fabrication techniques.