STM Journals Peer-reviewed research from Consortium e-Learning Network

Journal of Materials & Metallurgical Engineering Review Article

Heat Transfer by Arc Welding for A Similar Material Joint

  1. Md. Riazuddin Mechanical Engineering, NIST University, Berhampur
  2. Santosh Kumar Panda Mechanical Engineering, NIST University, Berhampur
  3. Achyutananda Parida Mechanical Engineering, NIST University, Berhampur
  4. Gedela Vasudev Mechanical Engineering, NIST University, Berhampur

Abstract

Electric arc welding (EAW) is a traditional fabrication process used in wider domestic, commercial and industrial application. Welding is a joining of two materials with the application of heat at the molecular level with the application of heat and pressure. Many materials used for welding application for different joining process. Maraging steel is special steel used for production of different air-craft components. Maraging material is used for heavy tools, producing strength, toughness, weld ability, and machine ability is good for any components. The investigation of heat transfer during the welding for a maraging steel surface provides a new topic for the research. The ranges of input parameters are voltage (35 to 55 V), current (70 to 90 V) and electrode diameter (5 to 20 mm). The study also predicts the effect of mode of heat transfer for the welding environment. The mode of heat transfer considered for the studies are convection on the variation of heat transfer coefficient and mixed effects of convection – radiation. The heat transfer coefficient is varies 0 to 100 W/m2 K. The present study considered the considerations such as voltage, current and electrode diameter to determine the weld energy produced through the welding. The study will also find the temperature profile, heat dissipation rate of the welding zone and work piece. The study will contribute to knowing the characteristics and phenomenon of electric arc welding for heat transfer phenomenon. The present work also helps to design and joining of the components for industrial and air craft components.

Keywords

References (40)

  1. Arora H, Mahaboob Basha K, Naga Abhishek D, Devesh B. Welding simulation of circumferential weld joint using TIG welding process. Materials Today: Proceedings. 2022;50:923-929. doi:10.1016/j.matpr.2021.06.315
  2. Arunkumar M, Dhinakaran V, Siva Shanmugam N. Numerical prediction of temperature distribution and residual stresses on plasma arc welded thin titanium sheets. International Journal of Modelling and Simulation. 2019;41(2):146-162. doi:10.1080/02286203.2019.1700089
  3. Aval HJ, Serajzadeh S, Kokabi AH. Theoretical and experimental investigation into friction stir welding of AA 5086. The International Journal of Advanced Manufacturing Technology. 2010;52(5-8):531-544. doi:10.1007/s00170-010-2752-x
  4. Ayoola WA, Suder WJ, Williams SW. Parameters controlling weld bead profile in conduction laser welding. Journal of Materials Processing Technology. 2017;249:522-530. doi:10.1016/j.jmatprotec.2017.06.026
  5. Baruah M, Bag S. Influence of pulsation in thermo-mechanical analysis on laser micro-welding of Ti6Al4V alloy. Optics & Laser Technology. 2017;90:40-51. doi:10.1016/j.optlastec.2016.11.006
  6. Campagnolo A, Ferro P, Romanin L, Meneghetti G. Residual Notch Stress Intensity Factors in Welded Joints Evaluated by 3D Numerical Simulations of Arc Welding Processes. Materials. 2021;14(4):812. doi:10.3390/ma14040812
  7. Chen J, Cao Z, Li J, Guo P, Sun Y. Double Wires Submerged Arc Welding Temperature Field Simulation. Proceedings of the 2nd International Conference on Electronic and Mechanical Engineering and Information Technology (2012). 2012. doi:10.2991/emeit.2012.339
  8. Chludzinski M, dos Santos RE, Churiaque C, Ortega-Iguña M, Sánchez-Amaya JM. Pulsed Laser Welding Applied to Metallic Materials—A Material Approach. Metals. 2021;11(4):640. doi:10.3390/met11040640
  9. Eruogun Etin-osa C. Analysis of Optimum Butt Welded Joint for Mild Steel Components Using FEM (ANSYS). Advances in Applied Sciences. 2017;2(6):100. doi:10.11648/j.aas.20170206.12
  10. Ebrahimi A, Hermans MJM. Laser butt welding of thin stainless steel 316L sheets in asymmetric configurations: A numerical study. Journal of Advanced Joining Processes. 2023;8:100154. doi:10.1016/j.jajp.2023.100154
  11. Farias RM, Teixeira PRF, Vilarinho LO. Variable profile heat source models for numerical simulations of arc welding processes. International Journal of Thermal Sciences. 2022;179:107593. doi:10.1016/j.ijthermalsci.2022.107593
  12. Wei H, Zhang Y, Tan L, Zhong Z. Energy efficiency evaluation of hot-wire laser welding based on process characteristic and power consumption. Journal of Cleaner Production. 2015;87:255-262. doi:10.1016/j.jclepro.2014.10.009
  13. He KF, Li XJ, Wu JG, Li Q. Three-Dimensional Temperature Field Numerical Simulation of Twin-Arc High-Speed Submerged Arc Welding Process Based on ANSYS. Advanced Materials Research. 2011;216:188-193. doi:10.4028/www.scientific.net/amr.216.188" rel="nofollow">doi:10.4028/www.scientific.net/amr.216.188
  14. Hejripour F, Binesh F, Hebel M, Aidun DK. Thermal modeling and characterization of wire arc additive manufactured duplex stainless steel. Journal of Materials Processing Technology. 2019;272:58-71. doi:10.1016/j.jmatprotec.2019.05.003
  15. Hossain I, Bhowmik A, Pattanaik A, Kumar R, Singh AK, Pandey S. Computational investigation of plasma arc welding process for aluminium alloys. Engineering Research Express. 2024;6(2):025541. doi:10.1088/2631-8695/ad4a24
  16. Tan H, Zhang Y, Liu Y, Fu X. ANSYS Workbench simulation of glass welding by femtosecond laser pulses. Infrared Physics & Technology. 2019;98:334-340. doi:10.1016/j.infrared.2019.03.036
  17. Rahman Chukkan J, Vasudevan M, Muthukumaran S, Ravi Kumar R, Chandrasekhar N. Simulation of laser butt welding of AISI 316L stainless steel sheet using various heat sources and experimental validation. Journal of Materials Processing Technology. 2015;219:48-59. doi:10.1016/j.jmatprotec.2014.12.008
  18. Jain R, Pal SK, Singh SB. Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy. Journal of The Institution of Engineers (India): Series C. 2016;98(1):37-43. doi:10.1007/s40032-016-0304-3
  19. Kumar N, Dewangan R, Rao KR. Analysis of reinforced friction stir welded joints of dissimilar Al and Cu-alloys by ANSYS software. Welding International. 2025:1-13. doi:10.1080/09507116.2024.2446254
  20. Kurashkin SO, Rogova DV, Tynchenko YA. Simulation of the electron beam welding process of a bimetallic ring by means of ANSYS. Journal of Physics: Conference Series. 2021;2094(4):042092. doi:10.1088/1742-6596/2094/4/042092
  21. The Physics of Welding. 1986. doi:10.1016/c2013-0-03805-4
  22. Lee CH, Chang KH. Three-dimensional finite element simulation of residual stresses in circumferential welds of steel pipe including pipe diameter effects. Materials Science and Engineering: A. 2008;487(1-2):210-218. doi:10.1016/j.msea.2007.10.011
  23. Liang R, Luo Y. Study on weld pool behaviors and ripple formation in dissimilar welding under pulsed laser. Optics & Laser Technology. 2017;93:1-8. doi:10.1016/j.optlastec.2017.01.029
  24. Murygin AV, Kurashkin SO, Tynchenko VS, Rogova DV. The use of ANSYS for modelling the energy distribution in steady mode with electron beam welding. Journal of Physics: Conference Series. 2021;1889(4):042061. doi:10.1088/1742-6596/1889/4/042061
  25. Padmanaban R, Kishore VR, Balusamy V. Numerical Simulation of Temperature Distribution and Material Flow During Friction Stir Welding of Dissimilar Aluminum Alloys. Procedia Engineering. 2014;97:854-863. doi:10.1016/j.proeng.2014.12.360
  26. Patterson T, Hochanadel J, Sutton S, Panton B, Lippold J. A review of high energy density beam processes for welding and additive manufacturing applications. Welding in the World. 2021;65(7):1235-1306. doi:10.1007/s40194-021-01116-0
  27. Reddy KS, Purushotham A, kala KL, Gupta MS, Kumar PK, Vemanaboina H. Thermal mapping of SS316L experimental and simulation for GTA welding process with moving heat source model using FEA. International Journal on Interactive Design and Manufacturing (IJIDeM). 2023;18(5):2755-2763. doi:10.1007/s12008-023-01310-y
  28. Sati P., Shukla D.K., and Tiwari S. K., (2022) Mechanical ANSYS Parametric Design Language Friction Stir Welding Simulation of AZ31B-H24 alloy, IOP Conf. Series: Materials Science and Engineering 1248, 012018. doi:10.1088/1757-899X/1248/1/01201
  29. Schnick M, Fuessel U, Hertel M, Spille-Kohoff A, Murphy AB. Numerical investigations of arc behaviour in gas metal arc welding using ANSYS CFX. Frontiers of Materials Science. 2011;5(2):98-108. doi:10.1007/s11706-011-0134-4
  30. Taskaya S, Kaya Gur A, Ozay C. Joining of Ramor 500 Steel with SAW (Submerged Arc Welding) and its Evaluation of Thermomechanical Analysis in ANSYS Package Software. Thermal Science and Engineering Progress. 2019;13:100396. doi:10.1016/j.tsep.2019.100396
  31. Sonawane H B and Deore E R., (2014) Finite element model for the effect of heat input & speed on residual stress during weldings International Journal of Mechanical Engineering and Robotics Research, vol. 3, pp. 763 ISSN 2278 – 0149 www.ijmerr.com
  32. Song M, Kovacevic R. Thermal modeling of friction stir welding in a moving coordinate system and its validation. International Journal of Machine Tools and Manufacture. 2003;43(6):605-615. doi:10.1016/s0890-6955(03)00022-1
  33. Sattari-Far I, Farahani MR. Effect of the weld groove shape and pass number on residual stresses in butt-welded pipes. International Journal of Pressure Vessels and Piping. 2009;86(11):723-731. doi:10.1016/j.ijpvp.2009.07.007
  34. Tamil Prabakaran S, Jerome S, Thirumal P, Shai Sundaram VS, Selvaraju S, Padmanabhan S. Thermal Modelling and Experimental Validation of TIG Welding Using ANSYS. Lecture Notes in Mechanical Engineering. 2022:307-316. doi:10.1007/978-981-19-0244-4_30
  35. Tsirkas SA, Papanikos P, Pericleous K, Strusevich N, Boitout F, Bergheau JM. Evaluation of distortions in laser welded shipbuilding parts using local-global finite element approach. Science and Technology of Welding and Joining. 2003;8(2):79-88. doi:10.1179/136217103225010899
  36. Vemanaboina H, Akella S, Buddu RK. Welding Process Simulation Model for Temperature and Residual Stress Analysis. Procedia Materials Science. 2014;6:1539-1546. doi:10.1016/j.mspro.2014.07.135
  37. Verma S, Meenu, Misra JP. Study on temperature distribution during Friction Stir Welding of 6082 aluminum alloy. Materials Today: Proceedings. 2017;4(2):1350-1356. doi:10.1016/j.matpr.2017.01.156
  38. Wei H, Zhang Y, Tan L, Zhong Z. Energy efficiency evaluation of hot-wire laser welding based on process characteristic and power consumption. Journal of Cleaner Production. 2015;87:255-262. doi:10.1016/j.jclepro.2014.10.009
  39. Xu H, Guo X, Lei Y, Lin J, Fu H, Xiao R, et al. Welding deformation of ultra-thin 316 stainless steel plate using pulsed laser welding process. Optics & Laser Technology. 2019;119:105583. doi:10.1016/j.optlastec.2019.105583
  40. Zhang YM, Yang YP, Zhang W, Na SJ. Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions. Journal of Manufacturing Science and Engineering. 2020;142(11). doi:10.1115/1.4047947
Support