A Thermo-Hydraulic Numerical Model for High Energy Welding Processes

Authors

  • Marc Medale Polytech' Marseille, Lab. de l'IUSTI, UMR 6595 CNRS - Université de Provence Technopole de Château-Gombert, 5 rue Enrico Fermi 13453 Marseille Cedex 13
  • Sylvain Rabier Polytech' Marseille, Lab. de l'IUSTI, UMR 6595 CNRS - Université de Provence Technopole de Château-Gombert, 5 rue Enrico Fermi 13453 Marseille Cedex 13
  • Charline Xhaard Polytech' Marseille, Lab. de l'IUSTI, UMR 6595 CNRS - Université de Provence Technopole de Château-Gombert, 5 rue Enrico Fermi 13453 Marseille Cedex 13 and CEA, Centre de Valduc, DAM/DFTN 21120 IS sur TILLE

Keywords:

welding processes modeling, moving interfaces, free surface flows, phase change, incompressible fluid flows, finite element method

Abstract

A numerical model especially devoted to the thermal simulation of high energy welding processes is proposed in this paper. It suggests one possible way to overcome the difficulty to simultaneously deal in the same numerical model with solid, liquid, and gas phases, together with their intense interactions. The proposed model results in a rather simplified model in the gas phase associated with a much more detailed one in the condensed phase (solid, liquid and mushy). The resulting numerical model is based on the finite element method, and features the dynamical evolution of the gas-liquid interface (key-hole) together with the liquid-solid one through an enthalpy formulation.

Downloads

Download data is not yet available.

References

Anisimov S.I., « Vaporization of metal absorbing laser radiation », Sov. Phys. JETP 27, 1968,

p. 182-183.

Ashcraft C., Grimes R., « SPOOLES: An Object-Oriented Sparse Matrix Library »,

Proceedings of the 1999 SIAM Conference on Parallel Processing for Scientific

Computing, San Antonio, Texas, USA, March 22-27, 1999.

Balay S., Gropp W.D., Mc Innes L.C., Smith B.F., « Efficient Management of parallelism in

object oriented numerical software librairies », Modern Software Tools in Scientific

Computing, Arge E. and Bruaset A.M. and Langtangen H.P. (Ed.), Birkhauser Press,

, p. 163-202.

Balay S., Buschelman K., Gropp W.D., Kauskik D., Mc Innes L.C, Smith B.F., Petsc home

page, 2003, (http://www.mcs.anl.gov/petsc).

Belytschko T., Liu W.K., Moran B., Nonlinear finite elements for continua and structures,

New York, J. Wiley & Sons Ltd., 2000.

Bennon W.D., Incropera F.P., « A continuum model for momentum, heat and species

transport in binary solid-liquid phase change systems - 1. Model formulation, 2.

Application to solidification in a rectangular cavity », Int. J. Heat Mass Transf., Vol. 30,

n° 10, 1987, p. 2161-2187.

Carey G.F., Oden J.T., The Texas Finite Element Series, Prentice-Hall, Englewood Cliffs,

New Jersey, 1986.

Crank J., Free and moving boundary problems, Oxford, Oxford University Press, 1984.

Dhatt G., Touzot G., Une présentation de la méthode des éléments fins, Paris, Maloine Ed.,

Duley W.W., Laser Welding, United States, Wiley Interscience, 1999.

Fabbro R., Chouf K., « Keyhole modeling during laser welding », J. Phys. D: Appl. Phys.,

vol. 87, 2000, p. 4075-4083.

Ganesh R.K., Faghri A., Hahn Y., « A generalized thermal modelling for laser drilling

process – I. Mathematical modelling and numerical methodology », J. Heat Mass

Transfer, vol. 40, 1997, p. 3351-3360.

Ganesh R.K., Faghri A., Hahn Y., « A generalized thermal modelling for laser drilling

process – II. Numerical simulation and results », J. Heat Mass Transfer, vol. 40, 1997, p.

-3373.

He X., Fuerschbach P.W., DebRoy T., « Heat transfer and fluid flow during spot welding of

stainless steel », J. Phys. D: Appl. Phys., vol. 36, 2003, p. 1388-1398.

Hirt C.W., Amsden A.A., Cook J.L., « An arbitrary Lagrangian-Eulerian computing method

for all flow speeds », J. Comput. Phys., vol. 14, 1974, p. 227-253.

Ho C.Y., Wen M.Y., « Distribution of the laser intensity absorbed by the keyhole wall in laser

processing », Journal of Materials Processing Technology, vol. 145, 2004, p. 303-310.

Hughes T.J.R., The finite element method: linear static and dynamic finite element analysis,

Prentice-Hall, Englewood Cliffs, New Jersey, 1987.

Hughes T.J.R., Liu W.K., Zimmermann T.K., « Lagrangian-Eulerian finite element

formulation for incompressible viscous flows », Comput. Methods Appl. Mech. Engrg.,

vol. 33, 1981, p. 329-349.

Jouvard J.-M., Girard K., Perret O., « Keyhole formation and power deposition in ND : YAG

laser spot welding », J. Phys. D: Appl. Phys., vol. 34, 2001, p. 2894-2901.

Kaplan A., Mizutani M., Katayama S., Matsunawa A., « Unbounded keyhole collapse and

bubble formation during pulsed laser interaction with liquid zinc », J. Phys. D: Appl.

Phys., vol. 35, 2002, p. 1218-1228.

Ki H., Mohanty P.S., Mazumder H., « Modelling of high density laser material interaction

using fast Level Set method », J. Phys. D: Appl. Phys., vol. 34, 2001, p. 364-372.

Knight C.J., « Theoretical modelling of rapid surface vaporization with back pressure »,

AIAA J., vol. 17, 1979, p. 519-523.

Knight C.J., « Transient vaporization from a surface into vacuum », AIAA J., vol. 20, 1982, p.

-961.

Medale M., Cerisier P., « Numerical Simulation of Bénard-Marangoni Convection in small

aspect ratio containers », Num. Heat Transf. A, vol. 42, 2002, p. 55-72.

Medale M., Jaeger M., Kaiss A. « Finite element analysis of the action of buoyancy induced

and thermocapillary flow on the melting of tin in a 2D square cavity », Comp. Ass. Mech.

Engrg. Sci., vol. 7, 2000, p. 307-320.

Ni J., Incropera F.P., « Extension of the continuum model for transport phenomena occuring

during metal alloy solidification - 1. The conservation equations, 2. Microscopic

considerations », Int. J. Heat Mass Transf., vol. 38, n° 7, 1995, p. 1271-1296.

Rabier S., Medale M., « Computation of free surface flows with a projection FEM in a

moving mesh framework », Comput. Methods Appl. Mech. Engrg., vol. 192, 2003, p.

-4721.

Rappaz M., « Modelling of microstructure formation in solidification processes », Int. Mater.

Rev., Vol. 34, 1989, p. 93-123.

Reddy M.P., Reddy J.N., « Numerical simulation of forming processes using a coupled fluid

flow and heat transfer model », Int. J. Num. Meth. Eng, Vol. 35, 1992, p. 807-833.

Semak W., Bragg W.D., Damkroger B., Kempkas S., « Temporal evolution of the

tempertaure field in the beam interaction zone during laser material processing », J. Phys.

D: Appl. Phys., vol. 32, 1999, p. 1819-1825.

Semak W., Matsunawa A., « The role of recoil pressure in energy balance during laser –

materials processing », J. Phys. D: Appl. Phys., vol. 30, 1997, p. 2541-2552.

Shyy W., Udaykumar H.S., Rao M.M., Smith R.W., Computational fluid dynamics with

moving boundaries, Washington D.C., Hemisphere, 1996.

Solana P., Kapadia P., Dowden J.M., Marsden P.J., « An analytical model for laser drilling of

metals with absorption within the vapour », J. Phys. D: Appl. Phys., vol. 32, 1999, p. 942-

Solana P., Negro G., « A study of the effect of multiple reflections on the shape of the

keyhole in the laser processing of materials », J. Phys. D: Appl. Phys., vol. 30, 1997, p.

-3222.

Sudnik W., Radaj D., Breitschwerdt S., Erofeew W., « Numerical simulation of weld pool

geometry in laser beam welding », J. Phys. D: Appl. Phys., vol. 33, 2000, p. 662-671.

Voller V.R., Prakash C., « A fixed grid numerical modelling methodology for convectiondiffusion

mushy region phase change problems », Int. J. Heat Mass Transf., vol. 24,

, p. 1709-1718.

Voller V.R., Swaminathan C.R., Thomas B.G., « Fixed grid techniques for phase change

problems: a review », Int. J. Num. Meth. Eng., vol. 30, 1990, p. 875-898.

Ytrehus T., Bergstrom T., « Theory and experiments on gas kinetics in evaporation in rarefied

gas dynamics », AIAA J., New York, edited by J.L Potter , 1977, p. 1197-1212.

Downloads

Published

2004-07-16

How to Cite

Medale, M. ., Rabier, S., & Xhaard, C. . (2004). A Thermo-Hydraulic Numerical Model for High Energy Welding Processes. European Journal of Computational Mechanics, 13(3-4), 207–229. Retrieved from https://journals.riverpublishers.com/index.php/EJCM/article/view/2345

Issue

Section

Original Article