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Mat.-wiss. u. Werkstofftech. 2017, 48, 1206–1212 Numerical investigation of droplet impact on the welding pool 1207
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1208 O. Mokrov et al. Mat.-wiss. u. Werkstofftech. 2017, 48, 1206–1212
rð1~
uÞ ¼ 0 ; ð1Þ the volume of metal fed from the wire is equal to
the volume of weld reinforcement, ym , xm are the
@h ~j2 boundaries of molten metal, x0 is the coordinate of
þ rð~uhÞ ¼ rðlrTÞ þ þ Sdh ; ð2Þ
@t s top surface before melting, rf is the radius of elec-
trode wire, uf is the velocity of electrode wire feed-
u
@~
1 þ ð~
u rÞ~
u ¼ rp þ rðmr~ uÞþ ing, uw is the welding velocity.
@t ð3Þ
The source terms considering the droplet inter-
gbA T þ~j B
1~ ~ þ !
Sdu ; !
action with the weld pool are given as Sdu ¼
rðs rfÞ ¼ 0 ; ð4Þ PN ! PN
ð1=dV Þ k¼1 f d Ak , Sdh ¼ ð1=dV Þ k¼1 qd Ak ;
~ ¼ r A;
B ~ ¼ m 0~j ;
~ r2 A ð5Þ !
where Sdu , Sdh are the local values of mechanical
momentum and heat sources due to the interaction
ur K1 rx 1ð~g ~
nÞðx xmax Þ ¼ Parc þ Pd ; ð6Þ
between the droplets and the liquid metal of weld
Zym pool; N is the instantaneous number of droplets that
uf are locally present in a volume dV, Ak is the sur-
ðxðxm ; yÞ x0 Þdy ¼ p r2f ; ð7Þ
uw !
0
face area of droplet, f ¼ ! u ~
d u m=r is the me-
d w
chanical interaction between the droplet and liquid
where 1 is the mass density, ~ u is the fluid flow ve-
metal of the weld pool. The change of the droplet
locity of liquid metal inside the weld pool, t is the
RT kinematic momentum is described by the ex-
time, h ¼ c1 dT þ c 1 h is the enthalpy, c is the !
0
pression: dð1~uÞ=dt ¼ f d ; qd ¼ ðT d T Þl=rw is the
heat capacity, c is the latent heat; h is the fraction of heat flux from the droplet to the weld pool, T d is
liquid metal, T is the temperature, ~j is the electrical the droplet temperature, T is the local temperature
current density, s is the electrical conductivity, l is of liquid metal. The change of the droplet heat con-
the thermal conductivity, p is the pressure, m is the tent is given by @hd =@t ¼ qd .
g is the acceleration due to gravity, bA is
viscosity, ~
Boundary conditions for heat flux on left
the thermal volumetric expansion coefficient of liq-
~ is the magnetic induction, f is the elec- ðy ¼ 0Þ, right ð y ¼ Y Þ, front ðx ¼ X Þ, back
uid metal, B
ðx ¼ 0Þ and bottom ðz ¼ ZÞ surfaces were defined
trical potential, linked to the current via Ohm’s law
~j ¼ srf, A is the vector potential and m 0 is the as (Equation 8). The heat flux on the top surface
ðz ¼ 0Þ was defined by (Equation 9).
permeability of vacuum, x is the free surface position
direction, u is the surface tension,
in zpffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
K¼ 1 þ ðrxÞ2 is the curvature of the free sur- @T
l ¼ qconv qradi ; ð8Þ
face, ~n is the vector normal to the free surface, n
@~
2
Parc ¼ 3m 0 I 2 = 4p2 rP exp 3 x2t þ y2 =r2P the @T
¼ qarc qconv qradi qevap ; ð9Þ
n
@~
arc pressure, rp is the arc pressure radius,
xt ¼ x0 uw t, where x0 and xt are the initial and the qconv ¼ aðT T out Þ; ð10Þ
time temporal position of the electrical
wire and t is
¼ 3
ð nÞnd =pr2d qradi ¼ s SB e T 4 T 4out ; ð11Þ
the time,
2 P
d 3=4pr
d 31 ~
u d ~
exp 3 xt þ y2 =r2d is the droplet impact pres-
qarc ¼ ðh I U W d Þ= 2pr2h exp 3 x2t þ y2 =r2h ;
ud , nd , rd are the droplet velocity, frequency
sure, ~
and droplet radius. ð12Þ
The deformation of weld pool free surface was where a is the Newton-Richman heat exchange co-
calculated using an equilibrium surface equation, efficient, sSB is the Stefan-Boltzmann constant, e is
considering the influence of surface tension, grav- the surface emittance, T out is the ambient temper-
ity, arc pressure and droplet impact pressure. xmax is ature, qevap is the evaporation heat flux, which is
determined by the integral equation of mass con- calculated by evaporation model, qarc is the arc
servation (Equation 7) due to the assumption that
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Mat.-wiss. u. Werkstofftech. 2017, 48, 1206–1212 Numerical investigation of droplet impact on the welding pool 1209
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1210 O. Mokrov et al. Mat.-wiss. u. Werkstofftech. 2017, 48, 1206–1212
sional shape of weld bead was obtained by a non- 5 Results and discussion
contact 3D laser profiling system, Figure 2.
A plan of experiments was made to obtain re- Comparative results for regimes 4 and 5 that are the
sults for a range of three main welding process vari- ultimate values of minimal 225 A and maximal
ables: welding current I, arc voltage U and welding 450 A welding current are given, Figures 3, 4, Ta-
velocity uw . The range of welding variables, ob- ble 3.
tained experimental data and calculated results of With a welding current of 225 A (regime 4) the
weld pool geometry are summarized, Table 3. The velocity of electrode melting is 7.8 mm/s, the de-
unknown model coefficients rh , rj , rp , rd were de- formation of the weld pool free surface is not sig-
fined due to the given range of experimental data. nificant, Figure 3, Table 3. The free surface of the
The relative calculation error estimated by size of liquid welding pool metal has no significant de-
D, B, G, L that was achieved is less than 10 %. formation as the arc pressure and droplet impact
flow have no significant influence. In this case, the
shape of the free surface is defined by the surface
tension force and the intensity of the metal mass in-
come due to the electrode melting rate. The con-
vective flow of liquid metal inside the weld pool is
formed mainly under the influence of thermo-grav-
itational and thermo-capillary forces. In this case,
the maximum velocity of liquid metal flow is
40 mm/s. The impact of the electromagnetic Lorentz
force and forced convection due to the droplets in-
come do not lead to a significant axial flow in
downward direction of the weld pool. In the central
part of the weld pool, ascending liquid streams are
formed, Figure 3. They transport most of the over-
heated metal from the arc area along the free surface
to the periphery of the weld pool. Near the solid-
ification borders, the convective streams of liquid
metal change to the opposite direction and move
along the bottom surface of the welding pool.
With a higher welding current of 450 A (regime
Figure 2. 3D scan of the melting surface, after blow out of 5) the velocity of electrode melting reaches
the liquid metal. 16.3 mm/s, the depression of the weld pool free sur-
Bild 2. 3D Scan der Schmelzoberfläche nach Ausblasen der face is 3.5 mm, Table 3, Figure 4. The comparison
Schmelze.
N I U0 vw D B G L D B G L
[A] [V] [mm min-1] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
experiment calculation
1 300 28 350 3.5 12.4 1.8 30.4 3.9 13.4 1.7 33.6
2 300 28 550 3.2 9.2 1.4 31.2 3.3 9.4 1.4 32.5
3 300 28 750 3.1 7.5 1.1 31.2 2.8 7.0 1.2 29.0
4 225 28 550 2.6 7.3 1.0 24.8 2.9 7.0 1.1 23.4
5 450 28 550 6.3 8.8 3.0 48.8 5.8 9.4 2.8 52.3
6 300 24 550 3.0 6.4 1.0 30.4 2.7 6.9 0.9 33.5
7 300 30 550 3.2 8.8 1.4 32.8 3.5 8.6 1.4 31.1
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Mat.-wiss. u. Werkstofftech. 2017, 48, 1206–1212 Numerical investigation of droplet impact on the welding pool 1211
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1212 O. Mokrov et al. Mat.-wiss. u. Werkstofftech. 2017, 48, 1206–1212
7 References [6] J.-W. Kim, S.-J. Na, Am. Weld. Soc. J., 1995,
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Phys. D: Appl. Phys., 2014, 47, 465204 Received in final form: July 31st 2017
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