Mass transport and solidification phenomenon in dissimilar metals arc welding

•Welding of dissimilar alloys is a cost-effective manufacturing process.•The possible defects such as mixing of the weld metals are serious challenges.•The numerical model is used to optimize the process parameters to improve mechanical properties.•The arc current increase led to the homogeneity of...

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Bibliographic Details
Published in:International journal of heat and mass transfer 2019-12, Vol.144, p.118703, Article 118703
Main Authors: Hejripour, Fatemeh, Helenbrook, Brian T., Valentine, Daniel T., Aidun, Daryush K.
Format: Article
Language:English
Subjects:
Arc welding
Computational fluid dynamics
Computer simulation
Dissimilar metals
Dissimilar metals welding
Fluid flow
Mass distribution
Mass transport
Mathematical models
Mechanical properties
Morphology
Predictions
Process parameters
Shape recognition
Solidification
Solidification characteristics
Temperature distribution
Transport phenomena
Weld metal
Welding parameters
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Summary:•Welding of dissimilar alloys is a cost-effective manufacturing process.•The possible defects such as mixing of the weld metals are serious challenges.•The numerical model is used to optimize the process parameters to improve mechanical properties.•The arc current increase led to the homogeneity of the weld zone.•The computed solidification parameters could describe the morphology of the weld zone. A 3D transient numerical simulation is developed to study the arc welding of dissimilar metals for three sets of processing parameters. The model is used to investigate the fluid flow impacts on mass transport during the process. The predicted mass distribution agrees well with experimental composition measurements obtained from electron dispersive spectroscopy (EDS) analysis. The temperature distribution and the top surface shapes also match well with the experimental data. The morphology of the weld metal has a crucial impact on the weldment’s mechanical properties, and the prediction of solidification structure is key to improving weld quality. To this end, thermal results are applied to analyze the solidification behavior of the weld pool. The solidification parameters are calculated at the weld pool interface and the results are compared with the observed morphology from the experiments. The experimental observations confirm the presence of asymmetric solidification as demonstrated by the proposed model.
ISSN:0017-9310
1879-2189
DOI:10.1016/j.ijheatmasstransfer.2019.118703