Modeling of Melt Flow and Heat Transfer in Stationary Gas Tungsten Arc Welding with Vertical and Tilted Torches
Abstract
:1. Introduction
2. Numerical Details
3. Governing Equations
- The arc is steady and in LTE;
- The flow is turbulent in the arc and laminar in the weld pool region;
- The length of the tungsten electrode tip surrounded by the arc plasma is the same for the 90° and 70° torch angles;
- The filler wire and the workpiece material are assumed to have similar properties;
3.1. Governing Equations of the Arc Plasma
3.2. Governing Equations of the Filler Wire
3.3. Governing Equations of the Weld Pool
4. Simulation Models
4.1. Model of the Arc Plasma
4.2. Model of Heat Transfer to the Filler Wire
4.3. Model of the Weld Pool
4.4. Boundary Conditions
5. Model Validation
6. Results and Discussion
6.1. Temperatures in the Arc, Filler Wire, and Workpiece
6.2. Convective Heat Flux to the Filler Wire
6.3. Electron Heat Flux to the Filler Wire
6.4. Total Heat Flux to the Filler Wire
6.5. Convective Heat Flux to the Workpiece
6.6. Electron Heat Flux to the Workpiece
6.7. Total Heat Flux to the Workpiece
6.8. The Weld Pool Shapes
7. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Parameters | Value |
---|---|
Arc length | 5 mm |
Welding current | 200 A |
Argon flow | 14 lt/min |
Torch angle | 90° and 70° |
Tip angle | 60° |
Electrode diameter | 3.2 mm |
Filler wire diameter | 2 mm |
Filler wire angle | 30° |
Filler wire feed rate | 100 cm/min |
Boundary | Description |
---|---|
a | Top of the arc domain |
b | Nozzle opening |
c | Tungsten electrode cross-section |
d | Tungsten electrode front symmetry plane |
e | Tungsten electrode tip surrounded by the plasma |
f | Arc–electrode interface |
g | Arc front symmetry plane |
h | Arc–workpiece interface |
i | Filler rod cross-section |
j | Filler rod front symmetry plane |
k | Arc–filler rod interface |
l | Outer of the arc domain |
m | Workpiece front symmetry plane |
n | Bottom of the workpiece |
o | Exterior of the workpiece |
p | Top of the workpiece |
Arc Domain (Fluid) | Torch Domain (Solid) | |||||||||
---|---|---|---|---|---|---|---|---|---|---|
Opening | Inlet | Sym. | Opening | Wall | Sym. | Interface | Interface | |||
Equation No. | Boundary Variable | Units | a | b | g | l | c | d | e | f |
(1) and (2) | U | m/s | - | - | - | - | - | - | ||
p | Pa | - | - | - | - | - | - | |||
(3) | T | K | 303 | 303 | 303 | 3000 | - | - | ||
q | W/m2 | - | - | - | - | - | - | 0 | 0 | |
(12) and (13) | E | V/m | 0 | 0 | - | 0 | - | constant | 0 | |
V | Volt | - | - | - | - | - | - | - | ||
A/m2 | - | - | - | - | - | -- | - | |||
(14) | B | A/m | Bn | Bn | Constant | - | Bn | constant | ||
T m | - | - | - | 0 | - | - | - | - |
Filler Wire Domain (Solid) | Workpiece Domain (Fluid) | |||||||||
---|---|---|---|---|---|---|---|---|---|---|
Wall | Sym. | Wall | Wall | Sym. | Wall | Wall | Wall | |||
Equation No. | Boundary Variable | Units | i | j | k | h | m | n | o | p |
(15) and (16) | U | m/s | - | - | - | - | 0 | 0 | 0 | |
p | Pa | - | - | - | Gas drag + Ma | - | - | - | - | |
(17) and (19) | T | K | 303 | - | - | 303 | 303 | 303 | ||
q | W/m2 | - | - | - | - | - | - | |||
hc | W/m2K | - | - | - | - | - | 20 | 20 | 20 | |
(12) and (13) | E | V/m | - | - | - | - | - | - | 0 | 0 |
V | Volt | - | - | - | - | - | Ground | - | - | |
J | A/m2 | - | - | - | - | - | - | - | ||
(14) | B | A/m | - | - | - | Bn | Constant | Bn | - | Bn |
T m | - | - | - | - | - | - | 0 | - |
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Parvez, S.; Siddiqui, M.I.H.; Ali, M.A.; Dobrotă, D. Modeling of Melt Flow and Heat Transfer in Stationary Gas Tungsten Arc Welding with Vertical and Tilted Torches. Materials 2021, 14, 6845. https://doi.org/10.3390/ma14226845
Parvez S, Siddiqui MIH, Ali MA, Dobrotă D. Modeling of Melt Flow and Heat Transfer in Stationary Gas Tungsten Arc Welding with Vertical and Tilted Torches. Materials. 2021; 14(22):6845. https://doi.org/10.3390/ma14226845
Chicago/Turabian StyleParvez, Shahid, Md Irfanul Haque Siddiqui, Masood Ashraf Ali, and Dan Dobrotă. 2021. "Modeling of Melt Flow and Heat Transfer in Stationary Gas Tungsten Arc Welding with Vertical and Tilted Torches" Materials 14, no. 22: 6845. https://doi.org/10.3390/ma14226845