Numerical simulation of heat transfer and fluid flow in GTA/Laser hybrid welding

B. Ribic, R. Rai, Tarasankar Debroy

Research output: Contribution to journalArticle

75 Citations (Scopus)

Abstract

In order to understand the temperature fields, cooling rates and mixing in the weld pool, a comprehensive, three-dimensional heat transfer and fluid flow model is developed and tested by comparing model predictions with two sets of experimental data. The first set of data was taken from the literature. The experiments varied the separation distance between the heat sources for three arc current levels at a constant laser power. The second set of experiments analysed the effect of varying laser power for a constant heat source separation distance. The results demonstrate that the distance between the two heat sources significantly affects the cooling rates. The calculated results showed that the hybrid weld pool was very well mixed with strong convection currents resulting from the interaction between the electromagnetic and Marangoni forces. The calculated and experimental results showed that hybrid welding increases the weld pool width and gap bridgability when compared with laser welding. The weld pool depth in hybrid welding was affected mainly by the characteristics of the laser beam. Hybrid weld pool penetration depth is maximised at an optimal distance between the arc electrode and laser beam. The cooling rate increases significantly when the heat sources are separated beyond a critical distance. At close separation between arc and laser, calculations show that the arc radius must be decreased to achieve the observed weld depths.

Original languageEnglish (US)
Pages (from-to)683-693
Number of pages11
JournalScience and Technology of Welding and Joining
Volume13
Issue number8
DOIs
StatePublished - Nov 1 2008

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welding
fluid flow
Flow of fluids
heat sources
Welding
Welds
heat transfer
Heat transfer
arcs
Lasers
Computer simulation
lasers
cooling
simulation
Cooling
Laser beams
laser beams
convection currents
laser welding
Source separation

All Science Journal Classification (ASJC) codes

  • Materials Science(all)
  • Condensed Matter Physics

Cite this

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abstract = "In order to understand the temperature fields, cooling rates and mixing in the weld pool, a comprehensive, three-dimensional heat transfer and fluid flow model is developed and tested by comparing model predictions with two sets of experimental data. The first set of data was taken from the literature. The experiments varied the separation distance between the heat sources for three arc current levels at a constant laser power. The second set of experiments analysed the effect of varying laser power for a constant heat source separation distance. The results demonstrate that the distance between the two heat sources significantly affects the cooling rates. The calculated results showed that the hybrid weld pool was very well mixed with strong convection currents resulting from the interaction between the electromagnetic and Marangoni forces. The calculated and experimental results showed that hybrid welding increases the weld pool width and gap bridgability when compared with laser welding. The weld pool depth in hybrid welding was affected mainly by the characteristics of the laser beam. Hybrid weld pool penetration depth is maximised at an optimal distance between the arc electrode and laser beam. The cooling rate increases significantly when the heat sources are separated beyond a critical distance. At close separation between arc and laser, calculations show that the arc radius must be decreased to achieve the observed weld depths.",
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Numerical simulation of heat transfer and fluid flow in GTA/Laser hybrid welding. / Ribic, B.; Rai, R.; Debroy, Tarasankar.

In: Science and Technology of Welding and Joining, Vol. 13, No. 8, 01.11.2008, p. 683-693.

Research output: Contribution to journalArticle

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