Reliable modeling of heat and fluid flow in gas-metal-arc fillet welds through optimization of uncertain variables

A. Kumar, T. DebRoy

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Although numerical heat transfer and fluid flow models have provided significant insight about fusion welding processes and welded materials in recent years, several model input parameters cannot be easily prescribed from fundamental principles. As a result, the model predictions do not always agree with the experimental results. In order to address this problem, the approach adapted here is to develop and test a model that embodies a heat transfer and fluid flow sub-model and an algorithm for optimizing and learning the values of uncertain process variables from a limited volume of experimental data. The heat transfer and fluid flow sub-model numerically calculates three-dimensional temperature and velocity fields and the weld geometry during gas metal arc (GMA) welding of fillet joints. The proposed model could estimate the unknown values of arc efficiency, effective thermal conductivity and effective viscosity as a function of welding conditions based on only a few experimental measurements. A vorticity-based mixing length hypothesis was also used to independently calculate the values of the effective viscosity and effective thermal conductivity. Good agreement between the experimental and the predicted weld geometry showed that this approach was useful in improving reliability of heat transfer and fluid flow calculations.

Original languageEnglish (US)
Title of host publicationTrends in Welding Research - Proceedings of the 7th International Conference
Pages85-90
Number of pages6
Publication statusPublished - Dec 1 2005
Event7th International Conference on Trends in Welding Research - Pine Mountain, GA, United States
Duration: May 16 2005May 20 2005

Publication series

NameASM Proceedings of the International Conference: Trends in Welding Research
Volume2005

Other

Other7th International Conference on Trends in Welding Research
CountryUnited States
CityPine Mountain, GA
Period5/16/055/20/05

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All Science Journal Classification (ASJC) codes

  • Materials Science(all)
  • Mechanical Engineering

Cite this

Kumar, A., & DebRoy, T. (2005). Reliable modeling of heat and fluid flow in gas-metal-arc fillet welds through optimization of uncertain variables. In Trends in Welding Research - Proceedings of the 7th International Conference (pp. 85-90). (ASM Proceedings of the International Conference: Trends in Welding Research; Vol. 2005).