NUMERICAL SIMULATION OF HEAT TRANSFER AND FLUID FLOW IN DOUBLE ELECTRODES TIG ARC-WELD POOL

doi:10.11900/0412.1961.2014.00401

Acta Metall Sin

2015, Vol. 51

Issue (2): 178-190 DOI: 10.11900/0412.1961.2014.00401

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NUMERICAL SIMULATION OF HEAT TRANSFER AND FLUID FLOW IN DOUBLE ELECTRODES TIG ARC-WELD POOL

WANG Xinxin¹, FAN Ding^1,²(

), HUANG Jiankang^1,², HUANG Yong^1,²

1 School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou 730050
2 State Key Laboratory of Advanced Processing and Recycling of Nonferrous Metals, Lanzhou University of Technology, Lanzhou 730050

Cite this article:

WANG Xinxin, FAN Ding, HUANG Jiankang, HUANG Yong. NUMERICAL SIMULATION OF HEAT TRANSFER AND FLUID FLOW IN DOUBLE ELECTRODES TIG ARC-WELD POOL. Acta Metall Sin, 2015, 51(2): 178-190.

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Abstract

Based on a developed unified three dimension (3D) mathematical model including two tungsten electrodes arc and weld pool for double electrode TIG arc heat source, the temperature, velocity, current density, magnetic flux and Lorentz force of the double electrodes TIG arc and the weld pool are obtained for SUS304 stainless steel. The simulated results are in fair agreement with the experimental results available. Buoyance, Lorentz force, plasma drag force, Marangoni shear stress and turbulent effect are taken into account to formulate the weld pool behavior and the effects of the each force on the flow of the weld pool are studied respectively. The heat flux and shear stress at the weld pool surface are analyzed as well. A dimensionless number Pe is used to compare the relative importance of convective heat and conductive heat in the weld pool. It is shown that non-axisymmetric double electrode arc results in the non-axisymmetric characteristics of the current density, heat flux, plasma drag force and Marangoni shear at the weld pool, and thus produces non-axisymmetric weld pool profiles. The evolution of the weld pool has little effect on the arc behavior. The plasma drag force of the double tungsten electrode TIG arc decreases significantly compared with that of the TIG arc. The Marangoni stress determines the weld pool flow and the heat convected dominates the heat transfer in the weld pool, their combination effect determines the heat transfer in the weld pool, which is the essential reason for the formation of the different weld pool profiles。

Key words: double electrode numerical simulation heat transfer non-axisymmetric dimensionless number

Received: 21 July 2014

ZTFLH:

TG402

Fund: Supported by National Natural Science Foundation of China (Nos.51074084 and 51205179)

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	Xinxin WANG
	Ding FAN
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https://www.ams.org.cn/EN/10.11900/0412.1961.2014.00401 OR https://www.ams.org.cn/EN/Y2015/V51/I2/178

Fig.1 Schematic of computation domain and boundary conditions

Area	v / (m·s^-¹)	T / K	?? $Φ$ / V	A / (Wb·m^-¹)
A	$v z = v (x, y)$	T=T(x, y)	$? Φ ? n = 0$	$? A ? n = 0$
B	$? (ρ v) ? n = 0$	$? T ? n = 0$	$? Φ ? n = 0$	A=0
C	-	Eq.(18)	$? Φ ? n = 0$	A=0
D	-	Eq.(18)	0	$? A ? n = 0$
E	-	1800	$- σ e ? Φ ? z = I π r c 2$	$? A ? n = 0$

Table 1 Boundary conditions

Table 2 Physical parameters used in the model^[19,25,43]

Fig.2 Temperature and flow fields in xz section (a, c) and yz section (b, d) of arc plasma and weld pool with pure Ar shielding (a, b) and Ar+O₂shielding (c, d) after spot welding for 2 s (T—temperature; F—voltage drop; T_m and v_m—maximum temperature and velocity, respectively)

Fig.3 Distributions of current density (a) and Lorentz force (b) of the arc and weld pool in xz section

Fig.4 Temperature and flow fields (a) and magnetic flux (b) at a location about 0.15 mm above the anode

Fig.5 Temperature fields at the anode surface (xy section) with pure Ar shielding (a) and Ar+O₂shielding (b) after spot welding for 2 s (Isotherms are in the unit of K)

Fig.6 Temperature distributions in x and y directions at the anode surface (xy section) with pure Ar shielding (a) and Ar+O₂shielding (b) after spot welding for 2 s (W_x and W_y —weld widths in x direction and y direction; d— position in x or y directions )

Fig.7 Current density and heat flux distributions in x direction (a) and y direction (b) at the anode surface (q_e and q_c are heat flux to the anode due to the electron absorption and the heat conduction, respectively; q_a is the total heat flux to the anode; j_z is the component of the current density in z direction)

Fig.8 Shear stresses in x direction (a, c) and y direction (b, d) at the weld pool surface with pure Ar shielding (a, b) and Ar+O₂shielding (c, d) about 2 s later after arc ignition (t—shear stress, t_p—plasma drag force, t_M—Marangoni shear stress, t_p+t_M—total shear stress)

Fig.9 Weld pool flows at xz sections (a, c, e, g, i) and yz sections (b, d, f, h, j) driven by buoyance (a, b), Lorentz force (c, d), surface tension ∂g /∂T<0 (e, f), surface tension ∂g /∂T>0 (g, h) and plasma drag force (i, j)

Fig.10 Weld pool geometry (a) and maximum velocity driven (b) by various forces (v_m—maximum velocity in the weld pool, D—weld depth, W—weld width, W_x and W_y —weld widths in x and y directions)

Fig.11 Variations of weld pool geometry (a) and maximas of heat flux and current density at the anode (b) with time (t)

Fig.12 Photographs of double electrodes TIG arc in xz section (a) and yz section (b)

Fig.13 Comparison between simulated and experimental weld pool profiles at xz section (a, c) and yz section (b, d) for pure Ar shielding (a, b) and Ar+O₂shielding (c, d)

Fig.14 Comparison between simulated and experimental weld pool geometries

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