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Research Papers

Three-Dimensional Modeling of Gas Metal Arc Welding of Aluminum Alloys

[+] Author and Article Information
H. Guo, H. L. Tsai

Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, 1870 Miner Circle, Rolla, MO 65409

J. Hu

Department of Mechanical Engineering, University of Bridgeport, Bridgeport, CT 06604jjhu@bridgeport.edu

J. Manuf. Sci. Eng 132(2), 021011 (Apr 21, 2010) (10 pages) doi:10.1115/1.4001479 History: Received June 24, 2009; Revised March 11, 2010; Published April 21, 2010; Online April 21, 2010

A three-dimensional mathematical model and numerical techniques were developed for simulating a moving gas metal arc welding process. The model is used to calculate the transient distributions of temperature and velocity in the weld pool and the dynamic shape of the weld pool for aluminum alloy 6005-T4. Corresponding experiments were conducted and in good agreement with modeling predictions. The existence of a commonly observed cold-weld at the beginning of the weld, ripples at the surface of the weld bead, and crater at the end of the weld were all predicted. The measured microhardness around the weld bead was consistent with the predicted peak temperature and other metallurgical characterizations in the heat-affected zone.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

A typical weld bead of GMAW of aluminum alloys

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Figure 2

Experimental setup and simulation domain of a GMAW system

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Figure 3

Partial three-dimensional view of the simulated weld at t=1.8800 s

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Figure 4

Side view showing the weld bead shape and weld pool at different times; the region with the darkest color is the weld pool and the second darkest region is the weld bead

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Figure 5

The corresponding temperature field of Fig. 4

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Figure 6

The corresponding velocity distributions of Fig. 4

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Figure 7

Front view showing the weld bead shape and weld pool

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Figure 8

The corresponding temperature field of Fig. 7

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Figure 9

The corresponding velocity distributions of Fig. 7

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Figure 10

Zones near the fusion line at the cross section of the weld: (a) zones near the fusion line and (b) base metal

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Figure 11

Comparison of the experimental and calculated results for a cross section at x=30 mm

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Figure 12

Knoop hardness measurement positions

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Figure 13

Knoop hardness measurement results and peak temperature along the hardness measurement line on cross section at x=30 mm

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