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    Thermal Efficiency Decision of Variable..

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    Rodolfo Moura

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    Imernatioal Journ of Wes and Mas easfer £38 (2019) 728-737 Contents Iisis available at SclanceDirect International Journal of Heat and Mass Transfer ELSEVIER journal homepage: www. F com/locate/ijhmt Thermal efficiency decision of variable polarity aluminum arc welding through molten pool analysis Hunchul Jeong, Kyungbae Park, Sungjin Baek, Jungho Cho” Schoo of MechancalEainenng, Chngbuk Naor Civ 1 hunger, Somaru Cheng 28644, Sep Kore layer on the surface by adopting varable polarity are welding. The autiors’ previous experimental research on the variable polarity are welding of aluminum alloy showed that reverse are polarity has la- {er heat tpt efficiency tha 2 stiaight polarity. Purthermare the authars have already developed 2 ‘numerical analysis model and suggested a methodology of estimating the heat input efficiency through 2 compation between faveeéimensional tolten pool simulation and ex epi ‘riot platy GTA wekng This escarch ta flow-up ofthe previous sy and reveals the umm Input eftcency of reverse pola arc in ahclnor welding fr the Br te inetod. A atest the hea inp elles of everse puaiy 38 Ue ages Una at of leh both poly in alamioum welding fowse © 2019 elevier Ld. A rights reserved eves panty Seas polenty Vanable polarity Votome a ie 1. introduction ‘he difficulty in assuring the weld quality without any defects using only @ conventional welding processes for aluminum alloys is well known, Ie is attributed to aluminum alley's high heat con- ductivity, thermal expansion coefficient, and hot crack susceptibil ity, a5 well a8 the generation of the porosities in the weldment based on the different hydrogen selubilty between the solid and liguid phases (1) and the existence of an aluminum oxide (AlO;) layer on the surface, Except for eliminating the altminum oxide layer, there isa limitation in controlling these aspects because they are inherent physical properties or characteristics of the material itself. Consequently, one ofthe few solutions to increasing the alu- minum weldability is to remove the oxide layer on the surface before ar during welcing. This can be achieved through a mechan= ical method using a wire brush, pickling, or an electtical method through a variable polarity (VP) are source whose current has an alternative square wave pattern in the direct current electrode positive (DCEP) or reverse polarity and dizect current electrode * Coresponding autor. mal ederee ngnoxhosebns 3c kr Ch). haps eiong0 201s/isectmassransfer 201804089 ive (DCEN) of straight polarity with a consistes [2.3] According to conventional theory with regard to the heat Input into the base metal during variable polarity are welding, it hhas been generally known that DCEN has higher heat input eff- ciency than DCEP polarity (4). Recently, however, quite different experimental results have been reported [5-8]. Cho et al. persua- sively described these pheniomena with newly suggested theeries, 2 combination of quantura tunneling effect and random walk of a cathode spot [8-10] Information with regard to the heat input efficiency for AC um welding has already been widely How: polarity during alum reported, and its values largely range from 0:21 te 0.83 (11 ever, such information isnot distinguishable with respect to gle polarity value, and only a combined value of AC welding has 's quite difficult to been mentioned, Despite the necessity, sitectly measure polarity in variable polarity welding through the experimental ‘method using a calorimeter. [rs rather easy to achieve a solution with help of a CFD-assisted method, ThereZore the main purpose of this paper is to indirectly determine the heat input efficiency by compating the simulation to the experiment. already been suggested, the details of which can be found in the authors’ previous paper [12 no FH Jeong tera 1 ural of Heat and Mass Transfer 188 (2018) 728-727 Nomenclature 3 ‘magnetic fix density magnetic fix density in 2 direction thickness of base metal specific heat volume fraction aceupied clectromagnectic force sravitational acceleration in z direction enthalpy convection coefficient welding current current density current density in z direction thermal conductivi electrical conductivity latent heat of fusion subscript of nom pres are pressure’ total enezay given by variable polaity welding energy given during DCEP duration energy given during DCEN duration elfective radius of are component temperature s subscript of tangential coraponent T; temperature in eastern centered cell T. temperature in eastern interfacial cell Ty liquidus temperature Ty Cemperature in northern centered cell Ty temperature in northern interfacial cell Te temperature in current cell Ty temperasure in southera centered cell T, temperature in southera interfacial ce Try solidus temperature Ty temperature m western centered cell Tq temperature in western incesfacial cell TL aeabient temperature Vv welding voltage Velocity vector field Vq velocity in normal direction x'y.2 Cartesian coordinate axis ‘Tj. unit veetor in x,y, z direction Greek symbols 5 volume thermal expansion coefficient 7 sutface tension. &—enissivity fue thecmal efficiency during DCEP fisw —_thecmal efficiency during DCEN H”—— éynamtc viscosity Him —- magnetic permeability of metal po ——- magnetic permeability im vacuum v kinematic viscosity ® ——pi,constan p density ° ormal stress Stefan-Boltzmann constant shear stress stress in tangential direction stress in x direction F stress in y rection In a numerical analysis model, the fuid is assumed as incom pressible, Newtonian, and laminar. The governing equations are ‘the continuity equation, momentum equation, and energy equse tion. In addition to these three basic equations, the conservative governing equation of the fluid fraction is accompanied to track the free surface of the fluid, which is the well-known volume of {uid (VOR) method. The analysis mode! is completed through the adoption of several ac welding characteristics such as the arc heat tux, ate pressure, Mazangon! lov, Buoyancy, and electromagnetic force as bounéary conditions or body force terms, The mathemat- ‘cal models applied to this research have already been verified 1n [15-20]. The previously verified 3-D numerical analysis model ‘can be «sed to conduct temperature and velocity field analyses and fiee-susface tacking in each cell by solving the four governing ‘equations above through the commercial package, Flow-3D. Except for the governing equations, all ac characteristics are reflected by ‘user subrout 2. Governing equations and boundary conditions ‘There are four governing equations used to realize the virtual are welding process. The first is the VOF method, which estiriates the volume fraction in each cell, The VOF technique is based on the variable Fa scalar denoting the volume fraccion of fluid occupying ceach cell, which (allows the conservation law. By definition, the value of Fis defined as zero in a voi cell, an¢ 1 ina fully occupied cell; otherwise, a value between zero ane 1 is applied, which i ognized as free surface elements Tae conservation of F is expressed as [21] DE_aF bm v. (VA) - ‘As mentioned before itis assumed that the fluid for this analy= sis s regarded as an incompressible, Newtonian, and laminar flow. Based on these assumptions, the continuity equation of the mass consezvation is expressed as vv=so (2) The momentum equation is als expressed as [22] bv a Typ BY Avr swV telat lt 3(Tx 8) Gh where the buoyancy force owing to the thermal expansion Mid in the weld molten pool is considered in the third term of tight side in Eq, (3), which is often referred to as a Roussinesq approximation, ‘The last term of Eq. (3) represents electromagnetic force which is described in detail through Eqs, (4) and (5) all the equations are according to schematic diagram of analysie domain seen in Fig. | The atest important aspect affecting the weld molten poo! behavior is the electromagnetic force through a combination of the current densicy that passes through the molten pool, and sts + Welding direction Fig. Sehematie diagram of ansytie domain a welding recon Jean rl nterationa ours of stand Mas Troe 8 (2018) 28-237 ™ resultant sel-induced magnetic fiel4, which plays a role as a body force in the weld molten pool, Basically, tae Lorentz force per unit of volume is tepresented as a crass product of the current density vector J and magnetic field vector @. FTF 4) ‘When electrons are transmitted from cathode to anode, they are always emitted or absorbed in a normal direction. i. the current density dizection is normal to the anode or cathode surtace. How ever, the weld pool surface always changes, and it therefore an extremely complex problem occurs if the electzomagnectic force is considered in the normal direction along the free surface a every single moment. Therefore, previous studies on che electromagnetic force during arc welding have created a simple model under the assumption that @ flat top surface is not a fee surface. Detailed descriptions for such aesumption are as follows, (1) The are current absorbed to the weld pool surface flows in ‘only tine normal direction (z-axis) on the x-y plane regardless cof the wave pattern of the pool. (2) The elecisical conductivity and magnetic permeability are considered as conscants. eH ai (2) The currene flux density according to the Gaussian distribu- tion is as follows: te aaee( a (4) The magnetic fhax density in the radial and height directions in a cylindrical coordinate system is assumed to be negligible (5) The current density that spreads in the radial direction in the ‘weld pool wall be equal on average throughout the entire thickness of the base metal ased on these several assump: sultant threes dimensional electromagnetic force model is simply derived in a Cartesian coordinate system as [22 Py Me fo Tere 5) i is important co apply the energy conservation equation to accurately estimate the temperature distribution during welding the related energy equation: becomes the following, ah ny. «cen By (9. Vyn-dy.ceor 6 » tet, fhe ote a) yT>ty ‘where the latent heat of fusion, ly, is divided into three cases with, egatd tof, the fraction of liquid phase between solidus and li: tuldus temperature, namely, a Solid state, mushy zone, and liquid state in a weld pool The top surface upon which the heat source is dicectly imposed is the region where the extreme leat flux is companied by ther ‘mal convection ang radiation emitted by the temperature itself. In adéition cts assemed that all gradients of the physica! properties in areas other than the top surface will be simply zero because the size of the actual base metal used in the experiment is too large to include it in the simulation domain owing te an u:inecessary loss oftime, and hence comparatively unimportant boundaries in terms of the heat transfer, except for the top surface, were dealt vath tusing continuative boundary conditions. The numerical expression of this becomes the following, x ° 9) where ® indicates any kind of physical properties, and m denotes ‘he normal direction on each plane, Basically, the heat loss by evaporation on the top surface of the weldment should be considered. However, it was assumed to be negligible because the arc welding has little influence on the evap- oration compared to a high-power density welding process, such as laser beam, plasms, and electron beam welding, Therefore, the boundary condicion of the top surface fora heat cransfer considers the arc heat flux, heat convection, and radiational heat loss. This is expressed as ar om Gin aT Ta) (tT Th) (10) Jn Bq, (10) above, the second and third terms on the right-hand side indicale the convectioail and radiational eat loss, respectively. The first term, qi, on the right-hand side denotes the arc heat flux whose fluctuating patterns in each DCEP and DCEN polarities are periodically repeated, which is classified into jy, heat flux daring DCEP duration and dyy, heat flax during DCEN «luration, For chis reason, the thermal efficiency was applied! difec- ently to each polarity through a mathematical model such as the fellowing easy =) n) \ w Sie Boyde + Ny zee cxf where nay dnoies the ate thermal efficiency ofthe DCEN polarity, Say for DCS. tres that che hes Supplied wth ron Zero ov ding DCEN perio, while 8 Zero atts te Ie cts ee veto for BEEP perio In ths research strategy to determine the thermal fcency in each vaable polarity is estbished by adapting the meshod to compare the Facets ofthe sirmlation with on experiment whic s another altematve for estating the out of hes the bese meal As indated in se Intedaction, an experimenca taper showed thatthe longer the DCEP dragon that 1s applied, thelarger area. Thevefore ite can match te propertionl com ‘Rant between the DCEP dy raio end the #2 aren we en deter tine the efficiencies in each poly. im Eq (11), YL apd Ta Genote the volage current and eflecive ae radius, respective Daring the ae welding proces the molten pool face ha to kinds of pressure boundary conetions One s presse by sie tension referred to asthe Laplace pressure and the oe is are pressure treo an are plasma low [2 hathematics expres Son of ths pressure boundary conditions onthe tp surge ean be expressed as lows ee 12) mm FH Jeong tera rear Bh eo ay) fq. (12) descibes the ptersare boundary condition at the top surface, and m denotes the normal directional component, The second term an the leftchand side in Eq, (12) ‘means the normal siress an the weld pool based on Newton's viscosity law. In the same equation, the second term on the rightsaand side describes the pressure through surface tension 7, and thus R, denotes the local surface curvature. The frst term on. the rightehand side is the are pressure, and is described through Fq. (12), One of the most interesting features in an are weld pool simu- lation is the fact that the metal surface is locally melted, and the resvilant temperature gradient through 3 Gaussian heat distribue tion therefore has quite a significant role. Even a slight difference in temperature gradient on the weld pool stface can cause a stvong shear force, which is referred to as a Marangoni flow, which hhas been newly reflected in the user-subroutine through coding Fg, (14) describes the bourdary condition through a Marangoni flow, ey dur a4) where subscripts, <,, and d)/AT denote the tangential componeat, tangential stress on the top surface of the weld pool, and the surface tension gradient, given as the thermo-bhysical property. respec tively. In practice, the top surface of a weld pool has a fuctuating ‘wave pattern, which means there is a large fractional -directional temperature gradient component in the direction perpendicular ro the xy plate, as shown in Fig. 1. Hence, its fect in itection is negligible because the heat flux distribution in the welding process. is generally in accordance with the two simersional Gaussian distribution on top veld pool surface, which leads to an extreme temperature gradient within the effective radius in the xy plane regatéless of the zedixection. For this reason, it rarely inuences the (op surface in the verical direction. 1s related mathematical model can be expressed inthe Cartesian coor dinate system as dar ange as) eat 4 OTR (16) Fig. 2 shows the mesh grid system used to explain 1 {for transforming Eqs. (15) and (15) into the discrete Eqs. (17) and (18) using the PVM. Here, each character, T, denotes each quadrant temperature away from current cel, Tp, Moreaver, Eee, Wee, Ss, and N-a indicate the eastern, western, southern, and aosthern loeae tions, respectively. The upper and lower case characters, T, repre- sent the temperature of the center ang the interface of the cell respectively. If accompanied by a mathematical technique 1nte- rating Eqs, (15) snd (16) with dx frem w to e, and dy fram s to 1, the results for the transformation into the discretization equa- tons can be derived as ff vtsiy 2 ff [Zany F.—eaxay 2 Tyay 51 Jura of Heat ant Mass Transfer 188 (2018) 728-727 5 aaa is wow * - Where each interfacial temperature, Ty,Tw,T,,andTy. is derived tzough the central differential scheme, which is determined based tn the average of the adjacent cells in the x ory direction. 3, Procedures of the experiment and simulation The base material used in both the experiment and simulation is a commercial wrought aluminum plate, A6061-T6, which is the most commonly used throughout all industries. ts related thermophysical properties

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