A unified model for coupling mesoscopic dynamics of keyhole, metal vapor, arc plasma, and weld pool in laser-arc hybrid welding

被引:25
作者
Chen, Xin [1 ]
Mu, Zhongyan [1 ]
Hu, Renzhi [1 ]
Liang, Lvjie [2 ]
Murphy, Anthony B. [3 ]
Pang, Shengyong [1 ]
机构
[1] Huazhong Univ Sci & Technol, State Key Lab Mat Proc & Die & Mould Technol, Wuhan 430074, Hubei, Peoples R China
[2] Huazhong Univ Sci & Technol, State Key Lab Digital Mfg & Equipment Technol, Wuhan 430074, Hubei, Peoples R China
[3] CSIRO Mfg, POB 218, Lindfield, NSW 2070, Australia
基金
国家重点研发计划; 中国国家自然科学基金;
关键词
Coupling mesoscopic dynamics; Dynamical keyhole; Dynamical weld pool; Metal vapor; Arc plasma; Laser-arc hybrid welding; NUMERICAL-SIMULATION; HEAT-TRANSFER; FLUID-FLOW; TRANSPORT PHENOMENA; PLUME; COEFFICIENTS; ATTENUATION; PRESSURE; ARGON; BEAM;
D O I
10.1016/j.jmapro.2019.03.034
中图分类号
T [工业技术];
学科分类号
08 ;
摘要
Although building a model of laser-arc hybrid welding has attracted substantial attention in recent decades, many problems remain. In particular, existing models failed to reproduce the highly transient (down to several tens of nanoseconds) physical interactions between solid, liquid, vapor plume and plasma occurring in the welding process. These interactions control the key physical processes of laser-arc hybrid welding and play dominant roles in process defect formation and final joint quality. Development of a unified model for laser-arc hybrid welding capable of modeling the multiphase physical interactions is faced with three major challenges. The first is how to decouple the highly correlated and mesoscopic interactions between the solid, liquid, vapor plume and plasma phases. The second and third are respectively the numerical treatments of the nonlinear discontinuous sheath layer between the arc plasma and the weld pool and the Knudsen layer between the vapor plume and the weld pool. In this study, we have developed a three-dimensional unified mathematical model that couples the mesoscopic dynamics of the arc plasma, keyhole, metal vapor, and weld pool in the laser-TIG hybrid welding process. To decouple the highly correlated gas, liquid, solid and plasma interactions, we proposed a novel approach in which the electromagnetic field in the workpiece (including solid and liquid phases) and outside the workpiece (gaseous phase and plasma) were continuously modeled globally, but in which the heat transfer and fluid flow are modeled separately within and outside of the workpiece and then coupled through boundary conditions. To treat the nonlinear interface between the arc plasma and weld pool outside the keyhole as well as between the vapor plume/plasma and the weld pool inside the keyhole, we proposed a novel ghost-fluid-based multiple timescale stepping algorithm. The results indicate that our model can be used to predict the time-dependent mesoscopic dynamics of vapor plume, plasma, keyhole and weld pool in a coupled manner. Good agreement was obtained between the numerical predictions and experimental results and literature data.
引用
收藏
页码:119 / 134
页数:16
相关论文
共 50 条
[21]   Numerical analysis of hybrid plasma in fiber laser-arc welding [J].
Gao, Zhongmei ;
Jiang, Ping ;
Shao, Xinyu ;
Cao, Longchao ;
Mi, Gaoyang ;
Wang, Yilin .
JOURNAL OF PHYSICS D-APPLIED PHYSICS, 2019, 52 (02)
[22]   Interactions between laser and arc plasma during laser-arc hybrid welding of magnesium alloy [J].
Liu, Liming ;
Chen, Minghua .
OPTICS AND LASERS IN ENGINEERING, 2011, 49 (9-10) :1224-1231
[23]   A desktop computer model of the arc, weld pool and workpiece in metal inert gas welding [J].
Murphy, Anthony B. ;
Vu Nguyen ;
Feng, Yuqing ;
Thomas, David G. ;
Gunasegaram, Dayalan .
APPLIED MATHEMATICAL MODELLING, 2017, 44 :91-106
[24]   Influencing of Molten Pool Dynamic Behavior on the Weld Formation during the Laser-Arc Hybrid Welding of 12 mm Thick Steel [J].
Li, Zufa ;
Xu, Liyun ;
Liu, Qingyong ;
Shang, Gang ;
He, Hanwu ;
Feng, Junbo ;
Zhang, Peilei ;
Yu, Zhishui .
STEEL RESEARCH INTERNATIONAL, 2024,
[25]   Analysis of the rapid central melt pool flow in hybrid laser-arc welding [J].
Alam, M. M. ;
Kaplan, A. F. H. .
LASER ASSISTED NET SHAPE ENGINEERING 7 (LANE 2012), 2012, 39 :853-862
[26]   Undercut suppression in laser-arc hybrid welding by melt pool tailoring [J].
Frostevarg, Jan ;
Kaplan, Alexander F. H. .
JOURNAL OF LASER APPLICATIONS, 2014, 26 (03)
[27]   Effect of Electric Field on Interaction Between Laser and Arc Plasma in Laser-Arc Hybrid Welding [J].
Chen, Minghua ;
Li, Xueyuan ;
Liu, Liming .
IEEE TRANSACTIONS ON PLASMA SCIENCE, 2012, 40 (08) :2045-2050
[28]   An easy-to-use multi-physical model to predict weld pool geometry in keyhole plasma arc welding [J].
Li, Yan ;
Su, Chen ;
Wang, Ling ;
Wu, Chuansong .
RESULTS IN ENGINEERING, 2022, 14
[29]   A Review of Numerical Simulation of Laser-Arc Hybrid Welding [J].
Wang, Zhaoyang ;
Gong, Mengcheng ;
Zhou, Longzao ;
Gao, Ming .
MATERIALS, 2023, 16 (09)
[30]   Modeling of the Weld Shape Development During the Autogenous Welding Process by Coupling Welding Arc with Weld Pool [J].
Dong, Wenchao ;
Lu, Shanping ;
Li, Dianzhong ;
Li, Yiyi .
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE, 2010, 19 (07) :942-950