5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December

12th14th, 2014, IIT

Guwahati, Assam, India

NUMERICAL ANALYSIS OF HEAT TRANSFER OF ARC

WELDED PLATE
Aniruddha Ghosh1, Pawan Kumar2, Arvind Kumar2*
Dept. of Mechanical Engineering, Govt. College of Engineering & Textile Technology,
Berhampore, WB, India
2
Dept. of Mechanical Engineering, Indian Institute of Technology, Kanpur, UP, India
(* corresponding author, e-mail: arvindkr@iitk.ac.in)

Abstract
In submerged arc welding process, the understanding of temperature distribution is essential in order to control the
dimension of heat affected zone and to get the required weld bead shape and size etc. Moreover, the temperature profile
is required to estimate the stress distribution in thermo mechanical analysis of the process. In this work, a numerical
solution for moving heat source with Gaussian distribution of heat flux density over the volume of oval shape is
derived using finite difference method. Heat transfer in welded plates during welding from fusion zone to heat affected
zone (HAZ) is assumed to be conductive heat transfer. Convective and radiative heat losses are also considered for
remaining zone of welded plate. With the help of the numerical solution, transient temperature distribution is estimated.
HAZ widths are also measured experimentally. Decent agreements between predicted and experimental values are
achieved.
Keywords: Submerged arc welding, Gaussian heat distribution, Oval heat source, Finite difference method.

1. Introduction
Critical investigation of the transient temperature
distribution is important for maintaining quality of the
submerged arc welding of plates. Temperature history of
welded components has a significant influence on
temperature distribution in the welded plate. Such
transient heat transfer problem having simple
geometries with simplified boundary conditions can be
solved analytically. But many problems encountered in
practice involve complicated geometries with complex
boundary conditions or variable thermo physical
properties, and cannot be solved analytically. In such
cases, sufficiently accurate approximate solutions can be
obtained using numerical method.
Goldak et al. (1984) proposed double ellipsoidal
heat source and the welding problem was analyzed by
ASGARD, a nonlinear transient finite element (FEM)
heat flow program. However, they have not considered
the convective heat loss. A three-dimensional, steadystate thermal model of the GMA welding process with a
moving coordinate framework was formulated by Pardo
and Weckman (1989) and was solved by the finiteelement method. Kumar and Bhaduri (1994) developed
a 3D finite element model to predict the transient
temperature distribution in the work piece for GMA
welding process. Their results were validated with
experimental data. Ohring and Lunt (1999) investigated
the gas metal arc weld pool considering radiation,
evaporation and viscous stress in the deformable free
surface boundary conditions. Sabapathy et al. (2000)

showed that numerical methods have ability to assess

the welding conditions for a safe welding of highpressure gas pipelines. A new mathematical description
of a heat-source was obtained with the help of
experimental data. Lindgren (2001) discussed
complexities involved in simulation of welding process.
Considering constant thermal properties, Yeh et al.
(2003) investigated numerically and experimentally the
temperature distribution of aluminum plates welded by
gas tungsten arc.
Klobcar et al. (2004) developed mathematical
modeling with the help of finite element method solving
by ABAQUS computer code of GTA weld-surfacing
process. It was found that double ellipsoidal heat source
assumption prevailed over ellipsoidal heat source
assumption in the comparison of numerical results and
experimental data for welded shape and thermal
welding cycles. Bianco et al. (2004) carried out two
numerical methods for two and three dimensional
models evaluating transient conductive fields with
moving heat source. Later, Bianco et al. (2004)
investigated transient three dimensional temperature
distributions numerically by COMSOL. Radiation and
convection modes of heat transfer from work piece
surfaces as well as variable thermo-physical properties
were taken into account. Cho (2006) investigated 3-D
numerical simulation of arc welding by using volume of
fluid technique. Comparisons of weld bead hump and
transient radius and temperature distribution on welded

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NUMERICAL ANALYSIS OF HEAT TRANSFER OF ARC WELDED PLATE

plates were made with experimental data. Mahapatra et

al. (2006) used three dimensional finite element analysis
to predict the effect of submerged arc welding process
parameters on temperature distribution and angular
distortions in single-pass butt joints with top and bottom
reinforcements. Elsen et al. (2007) described the
analytical and numerical solution of the heat conduction
equation for a localized moving heat source for use in
laser material processing viz. layered manufacturing and
laser alloying. Yeh et al. (2007) employed DouglasGunn scheme to solve 3D transient heat conduction
problem in gas tungsten arc welded plates. In addition,
experiment on aluminum plates was conducted to verify
the theoretical results. Scutelnicu et al. (2008) described
several results of theoretical and experimental
investigations on heat transfer in copper-low carbon
steel welded joints of thin plates. Convection and
radiation heat lost, and temperature-dependent thermophysical properties are considered in their model.
Measurements of the temperatures distribution have
been made during welding through infrared
thermography. Using the finite element code ANSYS,
Kazemi and Goldak (2009) developed a three
dimensional finite element model to simulate the bead
geometry of welded plates. The transient temperature
distribution as well as the dimensions of the weld bead
geometry during the welding process was calculated.
Biswas and Mandal (2010) considered a numerical
model and solved by the finite element package ANSYS
for single pass single sides submerged arc welding of
square butt joints.
In the present work, heat transport in submerged arc
welding of steel plates is investigated numerically,
through finite difference method, and experimentally. It
is assumed that heat is distributed on welded plate in
Gaussian distribution and shape of heat source is oval
type. The oval shape arises due to heat source and
convection in fusion zone. The aim of present work is to
study how this heat from this oval shape weld pool
(fusion zone) is being transferred to remaining of the
welded work piece that forms heat affected zone. The
mode of heat transfer is conduction for heat transfer
from fusion zone to heat affected zone. Parameters
controlling the oval heat source are obtained through the
measurement of weld pool geometry. Variable thermo
physical properties and convective and radiative heat
losses are taken into account in the proposed model.
Previously no work was attempted to find out transient
temperature distribution through finite difference
method and considering convective and radiative heat
loss, oval heat source, and variable thermo physical
properties. Practically during welding process thermo
physical properties are not constant and convective and
radiative heat transfer has a vital role.
Finally, a
simplified experiment is conducted to validate the
numerical results.

2. Experiment
A semi-automatic welding machine with constant
voltage and rectifier type power source with a 1200-A
capacity was used to join two C-Mn steel plates as butt
joint. The C-Mn steel work piece (30015020 mm) is
cut and V groove of angle 60o as per the standards are
prepared. The chemical composition of work piece
material is described in Table 1. One mm root opening
is selected to join the plates in the flat position keeping
electrode positive and perpendicular to the plate. The
job was firmly fixed to a base plate by means of tack
welding and then the submerged arc welding was finally
carried out. The welding parameters were recorded
during actual welding to determine their fluctuations, if
any. The slag was removed and the job was allowed to
cool down. Welding is carried out for the square butt
joint configuration. Temperatures were measured at
different points of the welded plates except welding line
by infrared thermometers (OMEGA SCOPE OS 524E,
temperature range 2482 C, accuracy is 1% or 2 C
whichever is greater, resolution 1 C, response time 10
ms). Finally the welded plate was cut at the center of the
bead to obtain 10 mm wide test specimens. The standard
metallographic process (i.e., metal polishing with a
series of empty sheets and disc polishing using diamond
paste from 5 m down to 0.5 m, was carried out. The
established color etching procedure for steel was
employed to identify different region of the weldment.
An optical research microscope (NEOPHOT-32) was
used for the purpose. With the help of the microscope
HAZ widths were measured.
Table 1 Chemical composition of C-Mn steel
work piece (in weight %)
C
0.18

Sn
0.36

Mn
1.58

P
0.023

S
0.027

S
0.027

Cr
0.06

Ni
0.03

Mo
0.01

Cu
0.04

Al
0.05

Al
0.05

Fe
97.5

Table 2 Submerged arc welding conditions and HAZ

Sl. No.
1
2
3
4
5
6
7
8

Heat input (kJ/cm)

30.88
43.24
39.71
55.59
17.50
24.50
22.50
31.50

HAZ width (mm)

2.37
3.45
2.63
3.93
2.19
2.27
2.25
2.39

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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th14th, 2014, IIT
Guwahati, Assam, India

3. Theoretical modeling
3.1 Heat source

Figure 1 Sketch of the work piece for submerged arc

welding process and Gaussian heat distribution

which describes the heat flux from the arc. It equals to

VI, where is the efficiency of the arc, V is the arc
voltage, and I is the welding current. Arc efficiency is
taken as unity for submerged arc welding process.
Let A, B, and C are the Oval Shape Bead Geometry
parameters. It should be pointed out that A is half of the
major axis of oval shape, B stands for half of the bead
width, and C represents penetration. In addition, values
of A, B, and C can be measured from weld bead
geometry. It is defined that the heat source energy at the
boundary between the molten pool and the base material
equals 0.05 q(0). Thus, in the x-direction:
2
q (A, 0, 0) = q(0)e aA =0.05 q(0)
(6)
Hence,
ln 20
3
a=

(7)
2
2
A
A
3
3
Similarly, it is derived that b
and c
(8)
2
2
B
C
Considering a rectangular region in which heat
conduction is significant in the x- and y-z-directions.
Heat is distributed on the welded plates. Let heat density
expression be
q& ( x, y , z , t ) = e

Figure 2 Oval heat source shape

For this study, it is assumed that heat is distributed
on welded plate through Gaussian manner (as shown in
Fig. 1) and shape of heat source is oval type (as shown
in Fig. 2).The equation of this 3D oval shape
(Khanna,1991), becomes
2
2
2 mx
(1)
=1
a x + ( b y + cz ) e
where, m=0.2, measured from experimental data. The
heat density q(x, y, z) at a point (x, y, z) (Goldak et al.,
1984) within oval shape is given by the following
equation:
q ( x , y , z ) = qo e

[ ax 2 + ( by 2 + cz 2 ) e mx ]

(2)

In equation (2), qo is Gaussian heat distribution

parameter and a, b, c, and m are oval heat source
parameters. If Q0 is the total heat input, then

2Q0 = q ( x, y , z ) dxdydz
(3)
Substituting equation (2) into equation (3) yields
m2
2 abc
qo =
e 4a Q0
3/2

(4)

Then, the oval shape heat distribution equation can be

rewritten as
m2
2
2
2 mx ]
2 abc [ 4 a + ax + ( b y + cz ) e
q ( x, y , z ) = Q0
e
(5)
3/ 2

In this study, Q0 is the heat input of the heat source

[ a ( xvt )2 +(by2 +cz 2 )emx ]

(9)
where, x, y, and z are the position of electrode at time t
and v denotes velocity of the moving heat source. Note
that ax2 in equation (2) is replaced by a(xvt )2 in
equation (9) since the electrode is moving.

3.2 Thermal properties

In this study, thermal conductivity, specific heat
capacity, thermal expansion coefficient, and Youngs
modulus of the work piece are all temperature
dependent. Due to the wide temperature interval
involved in the welding of C-Mn steel, from 30 C to
2500 C, it is required to take this dependence into
account. To facilitate computation, polynomial relations
were fitted form available experimental data (Biswas
and Mandal, 2010). The relations were derived in the
temperature intervals indicated below:
5 2
k(T) = 210 T 0.0135T + 52.2 (W/mK)
when, 20 C T 800 C
k (T ) = 0.0037T + 23.8 (W/mK)
when, 800 C <T 5000 C

For specific heat capacity,

6 3
2
Cp(T) = 410 T 0.0034T +1.0143T + 442.5
when, 20 C

T720 C

C p (T ) = 22543T

0.501

(10a)

(10b)

(11a)

(11b)

when, 720 <T 5000 C

For thermal expansion coefficient,

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NUMERICAL ANALYSIS OF HEAT TRANSFER OF ARC WELDED PLATE

(T ) = 0.0068T + 10.094 when,20

7 2
(T ) = 2 10 T + 0.0016T + 13.04

T550 C

(12a)
(12b)

when, 550 C <T 5000 C

The density of welded plates, , is 7806 kg/m3,

convective heat transfer coefficient, h, is 15 W/m2K,
8
Stefan-Boltzmann constant, , is equals to 5.67 10
2
4
W/m K , and the emissivity of the work piece, , is
assumed to be 0.95. In addition, arc efficiency, , is
taken as unity for this submerged arc welding process.

3.3 Boundary conditions

A specified initial temperature covering the entire
plate surface is
(13)
T = T for t= 0
Where T is the ambient temperature. During the
welding process, heat is dissipated into environment
through convection and radiation heat losses on the top
surface of the welded plate. Convection and radiation
heat losses are also assumed on the bottom surface. The
heat loss due to convection and radiation over these
surfaces is given by
k (T )

T
n

= h (T T ) + (T

4
T ) for t > 0

T
n

= h (T T )

for t > 0

The explicit finite difference equations are determined

on the basis of the energy balance for the transient case
expressed as

(16)

(14)

only convection heat transfer is considered for the

lateral surface of the work piece i.e.
k (T )

Figure 4 Description of meshes for the boundary of

the welded plate

(15)

Dividing a control volume of the work piece into a

rectangular mesh of nodal points spaced x, y, z apart
in the x, y, and z directions, and considering a general
interior node (m, n, o) (as shown in Fig. 3), the finite
difference form of equation (16) for the block
ABCDabcd (as shown in Fig. 4) can be expressed as

3.4 Finite-difference formulation

T m , n ,o

i +1

= (1 6 ) T m , n , o

k (T )
4 k (T )

i
i 2
i
i 2
i
i 2
(T
Tm1,n,o ) + (Tm,n+1,o Tm,n 1,o ) + (Tm,n,o +1 Tm,n,o1 ) (17)
m +1,n,o

where x = y = z = l , Fourier number, , is equal to

t
l

Figure 3 Representation of finite difference mesh

and the thermal diffusivity, , is defined as

k (T )

C p (T )

The explicit finite difference equations are determined

on the basis of energy balance. This can be achieved by
summing the heat flows into the rectangular control
volume adjacent to the boundary and equate them to the
energy stored within the control volume in time
step t . Due to similarity in appearance, some identical
forms are not given here and only selected transient
temperature distribution equations are given below
2 h l
i +1
i+
T
= (1
6 )T
m , n ,o

2 h l
k (T )

T + 2

k (T )

l
k (T )

m , n ,o

T 4 ( T m , n , o i ) 4

i
i
i
i
i
+ (Tm +1,n ,o + Tm 1, n,o + Tm , n +1,o + Tm ,n 1,o + 2Tm ,n ,o +1 )

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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th14th, 2014, IIT
Guwahati, Assam, India

i 2
q& ( x, y, z, t ) l

(18)

k (T )
As for the regions, GHJIghji, CDEFcdef, and
IJKLijkl can be, respectively, derived as

proposed explicit method to be conditionally stable, the

stability criteria (23) must be satisfied.

l
i 2hl
T 4 (Tm,n,oi )4
6 )Tm,n,o +
T + 2

k (T )
k (T )
i
2
q& ( x , y , z , t ) l
i
i
i
i
+ (Tm +1,n,o + Tm 1,n,o + Tm ,n +1,o + 2Tm ,n,o+1 ) +
(20)
k (T )

3.7 Grid independence

A careful check for the grid independence of
numerical solutions has been made to ensure the
accuracy and validity of the numerical schemes.
For this purpose, three grid systems, t=0.01 s and
x=y=z= 2 mm, t=0.01 s and x=y=z=1mm, and
t=0.002 s and x=y=z= 0.5 mm are tested. It is
found the maximum relative error in the temperature at
the center of the work piece between the latter two
solutions is within 1%. Spatial increments x, y, and
z of 1mm, and a time step t=0.01 s are thus adopted
in the calculation.

and

4. Results and discussion

l
i 2hl
T 4 (Tm,n,oi )4
6 )Tm,n,o +
T + 2

k (T )
k (T )
i
2
q& ( x , y , z , t ) l
i
i
i
i
+ (Tm +1,n,o + Tm ,n +1,o + Tm ,n 1,o + 2Tm ,n,o +1 ) +
(19)
k (T )

Tm,n,o

Tm,n,o

Tm,n,o

i +1

i +1

i +1

= (1

= (1

= (1

4hl

k (T )

4hl

k (T )

6hl
k (T )

6 )Tm,n,o +

2 hl
k (T )

T + 2

l
k (T )

T (Tm,n,oi )4

i 2
q& ( x , y , z , t ) l
i
i
i
+ (Tm +1,n ,o + Tm ,n +1,o + 2Tm ,n ,o +1 ) +
(21)
k (T )

3.5 Solution procedure

In this work, the governing equation (16) and the
boundary conditions Eqs. (13)-(15) are transformed into
a set of explicit finite difference equations (17)-(21) and
were solved numerically. The input data for this
calculation included the ambient temperature, the initial
temperature of the specimen, the size of the specimen
and of the elements of the mesh, the initial position of
the arc, the heat transfer coefficient, and the parameters
which characterized the arc. In order to ensure stability
of the calculations, the mesh size and time step has to be
limited. Considering equations (17)-(21), the dominant
stability criteria for all nodes is expressed as
t

2
l C p (T )

6 k ( T ) + hl

The stability condition is further given by

2
l C p ,min
t
6( k max + hl )

(22)

(23)

where C p,min and kmax are respectively the minimum

value of heat capacity and the maximum value of
thermal conductivity over the entire temperature range
of interest. The solutions of equation (16) subject to
boundary conditions (13)-(15) give the temperature
profile at each time step explicitly in terms of known
information from the previous time step. To assure the

Heat is transferred from fusion zone to heat affected

zone by conduction during the welding process. But
during heat flow from heat affected zone to remaining
zone, convective heat loss has also a vital role. It was
found from experiment that near weld line (i.e. at point
x=110mm, y=15mm), temperature was 1437 C (when
electrode was nearest to this point) but after 11 second
from reaching of peak temperature (i.e.1437 C)
temperature of this point was 1045 C, after 29 second
the temperature was 958 C and after 38 second
temperature was 919 C so rate of cooling was initially
high but it was decreasing with decrease of temperature
of welded plate. As the convection heat loss is
proportional to temperature difference between welded
plate and atmospheric temperature. Initially, temperature
difference between welded plate and atmospheric
temperature was larger but after some time temperature
difference was smaller so convective heat loss was also
low. It was found from time - temperature curve of
figure 5 that the rate of change of temperature is high
near the welding line as compared to that at a location
away from the welding line for the time range 0 50
second. This is due to convective heat loss and as the
electrode was reached at point x=110mm, y=0mm,
z=0mm, just after 22 second from starting point (0, 0, 0)
(as shown in Fig. 1).
Decent agreement between predicted data and
measured data has been achieved (Fig. 6).
In present work measured range of heat affected
zone width is 2.19 mm-3.93 mm (as described in table2).

530-5

NUMERICAL ANALYSIS OF HEAT TRANSFER OF ARC WELDED PLATE

Temperature(deg C)

1500
x=110mm,y=15mm
x=110mm,y=25mm
x=110mm,y=35mm
x=110mm,y=45mm

1000

500

0
0

50

100

150
Time(s)

200

250

300

Figure 5 Measured temperature variation w.r.t. time on welded plate

Temperature(deg C)

1500

1000

Estimated data
Measured data

500

0
0

50

100

150
Time(s)

200

250

300

Figure 6 Comparison between measured and estimated data at x=110mm, y=15mm

5. Conclusions
To estimate the transient temperature distribution on
welded plate in submerged arc welding process, the heat
source was assumed as oval in shape (oval shape raised
due to heat source and convection in fusion zone) and
thermo physical properties of materials were considered
as function of temperature. Convective and radiative heat
losses were also considered. The experimental
measurement shows that the peak temperature was higher
and the cooling rate was larger for a work piece closer to
welding path with respect to other part of welded plate as
convection heat loss is proportional to temperature
difference between welded plate and atmospheric
temperature. The numerical solution for oval shape heat
source was used to calculate transient temperatures at
selected points on C-Mn steel plates which were welded.

The estimated temperature distribution obtained through

finite difference method and those obtained from
experimental measurements compared fairly well with
variation up to 3% for the peak temperatures. It was
observed that the HAZ widths increase with increase in
heat input or arc energy. Because of high heat input the
heat removal rate is insufficient through convection
cooling, and as a result temperature near the welded zone
remains higher than the recrystallization temperature of
welded plate for a sufficient time.
The validated numerical predictions indicates that the
present solution could offer a good prediction for transient
temperatures near the weld pool, as well as away from
welding path. The newly developed heat source model has
predictive potential for various welding simulations.

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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th14th, 2014, IIT
Guwahati, Assam, India

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List of Symbols
a,b,c,m
A,B,C
Cp
h
I
k
l
q
Qo
t
T
U
V
x,y,z

Heat source parameters, mm

Bead geometry parameters, mm
Specific heat of work piece, J/kgK
Convective heat transfer coefficient, W/m2K
Current, amp
Thermal conductivity of work piece, W/mK
Mesh length, mm
Heat density, W/m3
Total heat input, W
Time, sec
Temperature, oC
Ambient Temperature, oC
Travel Speed (cm/min)
Voltage, Volt
Coordinates, mm
Thermal diffusivity, m2/sec
increment
Emissivity of the work piece
Arc efficiency

530-7

NUMERICAL ANALYSIS OF HEAT TRANSFER OF ARC WELDED PLATE

Density of workpiecec, kg/m3

Stefan -Boltzmann constant
(=5.6710-6 W/m2K4)
Mesh Fourier number

530-8