Thermal and mechanical coupled keyholing process in moving plasma arc welding

doi:10.11949/j.issn.0438-1157.20160614

CIESC Journal ›› 2016, Vol. 67 ›› Issue (S1): 69-75.DOI: 10.11949/j.issn.0438-1157.20160614

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Thermal and mechanical coupled keyholing process in moving plasma arc welding

LI Yan¹, FENG Yanhui^2,3, ZHANG Xinxin^2,3, WU Chuansong⁴

1 State Key Laboratory of Heavy Oil Processing, China University of Petroleum, Beijing 102249, China;
2 School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100083, China;
3 Beijing Key Laboratory of Energy Saving and Emission Reduction for Metallurgical Industry, University of Science and Technology Beijing, Beijing 100083, China;
4 Key Laboratory for Liquid-Solid Structure Evolution and Materials Processing, Ministry of Education, Shandong University, Jinan 250061, Shandong, China

Received:2016-05-09 Revised:2016-05-19 Online:2016-08-31 Published:2016-08-31
Supported by:
supported by the Science Foundation of China Petroleum, Beijing (2462015YJRC013) and the National Natural Science Foundation of China (50936003).

等离子弧移动焊接的热-力耦合穿孔过程

李岩¹, 冯妍卉^2,3, 张欣欣^2,3, 武传松⁴

1 中国石油大学(北京)重质油国家重点实验室, 北京 102249;
2 北京科技大学机械工程学院, 北京 100083;
3 北京科技大学冶金工业节能减排北京市重点实验室, 北京 100083;
4 山东大学材料液固结构演变与加工教育部重点实验室, 山东济南 250061

通讯作者: 冯妍卉,yhfeng@me.ustb.edu.cn
基金资助:
中国石油大学（北京）科研启动基金项目（2462015YJRC013）；国家自然科学基金项目（50936003）。

Abstract

Abstract:

Due to the strong heating effect and arc force, plasma arc welding (PAW) can instantly melt metal material and then penetrate through the molten metal, forming a vapor-filled cavity called as "keyhole". The arc temperature is extremely high in keyhole, and thus a large percentage of heat is able to be transferred to the bottom metal through the keyhole. With respect to the moving PAW, a keyhole-tracking heat source was developed to reflect the nonuniform heat transfer due to welding movement. It consists of a double-elliptical heat flux on top surface and a lower developing conical heat source proportional to the keyhole growth. The volume of fluid (VOF) method was applied to track keyhole interface, and the heat source was auto-controlled according to keyhole depth. By numerical simulation, heat transfer during the keyholing process was revealed and corresponding temperature field was calculated to display the thermal-physical mechanism in moving PAW. Moreover, keyhole evolution and molten metal flow in weld pool were also investigated to exhibit how the keyhole promotes deep penetration welding. Finally, experiment was carried out on stainless steel plate of thickness 8 mm, and the measured weld geometry and size coincide with simulation results.

Key words: moving plasma arc welding, heat transfer, keyhole, gas-liquid flow, volume of fluid, numerical simulation

摘要：

等离子弧焊接中，强电弧可以穿透工件，在焊接熔池内形成一个充满高温电弧的小孔，热量由小孔内的电弧直接传输给下部工件，有利于焊接大厚度的工件。针对移动焊接工况开发出一种耦合小孔演变的热源模型。上表面采用双椭圆面热源，有效地表征工件运动引起的热量不均匀分布；下部采用动态增长的椎体热源，热源作用区域随小孔生长而增大。应用流体体积函数法（VOF）追踪小孔界面，将小孔深度作为热源参数调控热源动态增长。数值模拟获得了移动焊接的小孔传热机理和相应的温度场，同时详细考察了小孔界面及熔池内流动的演变过程。通过实验对比焊接熔池的形状尺寸，验证了该模型的正确性。

关键词: 等离子弧移动焊接, 传热, 小孔, 气液两相流, 流体体积函数, 数值模拟

CLC Number:

TK121

LI Yan, FENG Yanhui, ZHANG Xinxin, WU Chuansong. Thermal and mechanical coupled keyholing process in moving plasma arc welding[J]. CIESC Journal, 2016, 67(S1): 69-75.

李岩, 冯妍卉, 张欣欣, 武传松. 等离子弧移动焊接的热-力耦合穿孔过程[J]. 化工学报, 2016, 67(S1): 69-75.

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Thermal and mechanical coupled keyholing process in moving plasma arc welding

等离子弧移动焊接的热-力耦合穿孔过程

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