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IMECE2013
November 15-21, 2013, San Diego, California, USA
IMECE2013-64503
ABSTRACT
This study is focusing on understanding the thermal stress
formation in hybrid laser-MIG welding which has been gaining
a lot of interests due to its many advantages over laser welding.
Thermal stress formation is tightly associated with heat and
mass transfer in hybrid laser welding, so accurate analysis of
heat transfer process in the welding process is critical to
correctly predict thermal stress information and residual stress
in hybrid laser welds. In this study, a comprehensive heat and
mass transfer model analyzing the energy, mass, and
momentum transport processes in hybrid laser-MIG welding is
successfully integrated with a mechanical model to study
thermal stress formation in hybrid laser-MIG welding and
residual stress in final welds as well. High compressive stress
is found to exist on the top surface of the weld which might
cause irregular welds topology and high tensile residual
stresses were found in some locations in the final weld. This
proposed study can be used as a foundation to further
understand the thermal stress formation mechanisms in welding
and to provide an efficient way to optimize the hybrid laser-arc
welding process.
INTRODUCTION
Laser welding has been recently used in many industries
due to its many advantages over traditional welding techniques,
such as deep penetration, precise operation, short processing
time, etc. [1-3].Welding with lasers is characterized by creating
a keyhole inside the molten metal. A high-energy-density beam
vaporizes the workpiece during the welding process to form a
deep hole, which is called the keyhole. The keyhole increases
the coupling of laser energy into the workpiece, resulting in a
weld with high depth-to-width ratio and a narrow heat-affected
zone. However, in laser keyhole welding, the highly-localized
heating and non-uniform cooling results in high temperature
gradient during heating and cooling periods, thus a high
Hai-Lung Tsai
Dept. of Mechanical and Aerospace Engineering
Missouri University of Science and Technology
Rolla, MO 65409, USA
Plasmazone
Solidliquid
interface
Metalzone
z
r
welds as well.
Despite a large number of studies on hybrid laser-arc
welding, most of these studies focus on conducting
experiments to effectively integrate laser and arc welding
together. There are limited theoretical studies investigating the
(1)
V 0
Momentum Equations
p ul
C 2
( u ) ( Vu ) l
(u us ) 0.5 u u s (u u s )
u
K l
t
l
r K l
(2)
( f s flVr ur ) s u
m 1
t pl pl
0
pl
zo
zm
(6)
(V ) F 0
t
dt
(7)
p ul
C 2
( v ) ( Vv ) g l v
(v vs ) 0.5 v vs (v vs ) (3)
t
K l
l
z K l
g T (T T0 )
l
( f s flVr vr ) s v
Energy Equation
k
( h) ( Vh) h ( hs h) (V Vs )( hl h)
c
t
p
(4)
Specie Equation
( f ) ( Vf ) Df D ( f l f ) (V Vs )( f l f )
t
(5)
Fig. 2 Temperature-dependent thermal properties of SS304
t = 15.0 ms
t = 25.0 ms
2.5
2.5
z (mm)
3.5
z (mm)
3.5
1.5
1.5
t = 19.0 ms
t = 33.0 ms
3.5
3.5
z (mm)
2.5
z (mm)
2.5
1.5
1.5
t = 22.0 ms
t = 48.0 ms
3.5
3.5
z (mm)
2.5
z (mm)
2.5
1.5
1.5
-1
0
r (mm)
-1
0
r (mm)
t = 25.0 ms
3.5
3.5
10 cm/s
25 cm/s
2.5
2.5
z (mm)
z (mm)
1.5
1.5
t = 19.0 ms
3.5
25 cm/s
10 cm/s
z (mm)
2.5
z (mm)
2.5
1.5
1.5
t = 22.0 ms
t = 48.0 ms
3.5
3.5
25 cm/s
5 cm/s
z (mm)
2.5
z (mm)
2.5
1.5
1.5
t = 33.0 ms
3.5
-1
0
r (mm)
-1
0
r (mm)
t = 25.0 ms
2.5
2.5
z (mm)
3.5
z (mm)
3.5
1.5
1.5
t = 19.0 ms
t = 19.0 ms
3.5
(a)
t = 33.0 ms
3.5
3.5
T (K)
3290
2.5
2.5
3091
2892
2692
2493
1496
1.5
1.5
z (mm)
1895
1695
2.5
2094
z (mm)
z (mm)
2294
1297
1097
898
699
499
1.5
t = 22.0 ms
t = 48.0 ms
3.5
3.5
z (mm)
2.5
z (mm)
2.5
1.5
1.5
(b)
1
-1
0
r (mm)
-1
0
r (mm)
(c)
Fig. 7 Residual stress components: (a) Von Mises, (b) Normal stress
(x), and (c) Von Mises with inflated deformation geometry
CONCLUSIONS
A comprehensive thermal model has been used to study the
transport phenomena, such as heat transfer, melt flow,
solidification, and cooling in hybrid laser-MIG welding. This
model is then integrated with a mechanical model to study the
thermal stress evolution and thermal residual stress in hybrid
welding. As indicated, high compressive stress exists on the top
surface of the weld which might cause irregular welds topology
(bumps). High residual tensile stress value (over the critical
value of the materials) was found in some locations in final
welds. It indicates that thermal cracking is most likely to appear
in this region, which agrees with some experimental
observations. The magnitude of thermal stress and residual
stress are found a bit higher in hybrid laser-MIG laser welding
than those in laser welding, which may be due to the additional
energy and momentum input from the droplets into the weld
pool in hybrid laser-MIG welding simulation which affects the
cooling process in solidification. More studies will be carried
and discussed later. In summary, the proposed study can
provide an efficient way to further investigate the hybrid laserarc welding process, such as reducing residual stress in welds;
controlling welds surface topology; preventing thermal
cracking in welds; and optimizing hybrid laser-arc welding
process.
REFERENCES
1. Ishide, T., Tsubota, S., Nayama, M., Shimokusu, Y.,
Nagashima, T., and Okimura, K., 10 kW class YAG laser