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DOI 10.1007/s00170-012-4048-9
ORIGINAL ARTICLE
Received: 27 July 2011 / Accepted: 5 March 2012 / Published online: 21 March 2012
# Springer-Verlag London Limited 2012
Abstract This paper is an attempt to list the recent developments in the area of arc welding heat transfer simulation.
Fusion welding modeling is a broad area where a number of
research groups were spending their efforts to get solutions
for both research and industrial problems. Starting from
fundamentals of arc physics, heat transfer, microstructure
models, thermal stress, and modern techniques like pattern
recognition comes into picture while considering the complete solution of welding-related problems. These areas are
developing almost independently and there are only few
efforts to couple them together as computational welding
mechanics, which includes the computational fluid mechanics,
magneto hydrodynamics, thermo mechanical problems, and
computational material science. Here, an effort is made to list
down major developments in this area and to plot the present
state of research on the TIG welding heat transfer modeling by
giving priority to last few years of research.
Keywords Welding . Simulation . TIG . Heat
transfer . Modeling
1 Introduction
Welding is extensively employed as the joining technique
for metals and alloys in many manufacturing industries. The
V. M. J. Varghese (*)
Sree Chitra Thirunal College of Engineering,
Thiruvananthapuram, India
e-mail: mailtojoy2@yahoo.com
M. R. Suresh : D. S. Kumar
Vikram Sarabhai Space Center,
Thiruvananthapuram, India
750
751
of repair welding of tools which was also based on conduction model and they were able to predict the temperature
profiles successfully. Goncalves et al. [22] solved 3D inverse problem of welding heat transfer using golden section
technique. Those researchers who predict the thermal stress
made use of conduction models in order to reduce the
solution time.
Since 1980, many papers were published by considering
the magnetic and hydrodynamic effects inside the weld
pool. The effect of various governing forces in the weld
pool on pool shape, velocity distributions, surface depressions, etc. have been studied by many researchers. Initially,
the simulations were based on assumed weld pool shapes,
and later predicted weld pool shapes were used. Models are
available for both full penetration and partial penetration.
Kim et al. [23] developed 2D axisymmetric model for fluid
flow and heat transfer in the weld pool with consideration of
all the four driving forces of convection, electromagnetic,
buoyancy, surface tension, and drag forces. Fan et al. [24]
developed a numerical model for heat and fluid flow inside
weld pool that can be applied to both partial penetration and
full penetration. Taylor et al. [25] applied finite volume
method to welding phenomenon and they were able to
predict the Marangoni convection which arises because of
difference in surface tension in the weld pool. Recently, the
effect of an external magnetic field on the weld pool is modeled by Lin et al. [26] while a numerical model for doublesided arc welding is presented by Wu et al. [8].
3.4 Determination of thermal stress
752
detailed finite element model for uncoupled thermomechanical solution of residual stress is presented by Anca et al. [32].
Most of these researches deal in heat distribution models for
thermal profiles and none of them consider the convection
currents in the weld pool while calculating the stress field in
the weld pool boundaries. The experimental results presented
by Xu et al. [33] prove that the convection in the weld pool
significantly affects the penetration and weld pool shape and
there by the stress distributions. Residual stress models incorporating convection effects are yet to be formulated.
6 Conclusion
The fundamental research in welding modeling began in
1942, but still the research is at a developing stage. In areas
like distortion prediction, hot cracking, etc. accurate models
are yet to be developed. The idea of computational welding
mechanics is a new concept considering all the thermomechanical and metallurgical effect during welding, and no
model is developed so far by considering all these effects.
Recently, the models for prediction of microstructure are
making use of convection models, but for predictions of
thermal stress we are still depending upon conduction models.
In the case of multipass welding, the time taken to solve the
model is a major limiting criterion. Techniques like variable
meshing and adaptive meshing can be applied to reduce the
time.
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