径向超声波辅助MIG焊电弧的数值模拟

doi:10.1007/s12204-021-2380-7

J Shanghai Jiaotong Univ Sci ›› 2024, Vol. 29 ›› Issue (2): 330-338.doi: 10.1007/s12204-021-2380-7

径向超声波辅助MIG焊电弧的数值模拟

洪蕾1，肖皓1，叶佳2，马国红1

（1.南昌大学机电工程学院江西省轻质高强结构材料重点实验室，南昌 330031；2. 应用材料公司，美国圣塔克拉拉 95054-3299）

收稿日期:2021-01-06 接受日期:2021-03-29 出版日期:2024-03-28 发布日期:2024-03-28

Numerical Simulation of Radial Ultrasonic Assisted MIG Welding Arc

HONG Lei¹ (洪蕾), XIAO Hao¹ (肖皓), YE Jia² (叶佳), MA Guohong^1* (马国红)

(1. Key Laboratory of Lightweight and High Strength Structural Materials of Jiangxi Province, School of Mechanical Engineering, Nanchang University, Nanchang 330031, China; 2. Applied Materials, Inc., Santa Clara, CA 95054-3299, USA)

Received:2021-01-06 Accepted:2021-03-29 Online:2024-03-28 Published:2024-03-28

摘要/Abstract

摘要： 对传统的熔化极惰性气体保护（MIG）焊和超声波辅助熔化极惰性气体保护（U-MIG）焊电弧进行了数值模拟。基于Fluent软件建立的模型，对电弧形状、温度场和电势分布进行了模拟。研究发现，径向添加超声波后，电弧的形状发生了变化；电弧的高温区域拉长，温度峰值增大。但随着电流的增大，温度的升高幅度减小。此外，在相同的条件下，U-MIG的电位降低，工件上的压力增加。为了验证仿真结果的准确性，进行了相同条件下的焊接实验，并利用高速摄像机采集电弧的动态图像。仿真结果与实验结果吻合良好，为超声辅助电弧焊提供了一定的参考价值。

关键词: 数值模拟，焊接电弧，超声波弧焊，电弧温度

Abstract: The numerical simulation of arc was carried out for both conventional melt inert gas (MIG) welding and ultrasonic assisted melt inert gas (U-MIG) welding. Based on the model established by Fluent, the arc shape, temperature field, and potential distribution were simulated. The study found that the shape of the arc changed when ultrasonic was added radially; the high-temperature area of the arc stretched, and the temperature peak increased. But as the current increased, the increase in temperature decreased. In addition, under the same conditions, the potential of U-MIG decreased and the pressure on the workpiece increased. To verify the accuracy of the simulation results, welding experiments under identical conditions were carried out, and a high-speed camera was used to collect dynamic pictures of the arc. The simulation results were in a favorable agreement with the experimental results, which provided a certain reference value for ultrasonic assisted arc welding.

Key words: numerical simulation, welding arc, ultrasonic arc welding, arc temperature

中图分类号:

TG444

洪蕾1，肖皓1，叶佳2，马国红1. 径向超声波辅助MIG焊电弧的数值模拟[J]. J Shanghai Jiaotong Univ Sci, 2024, 29(2): 330-338.

HONG Lei¹ (洪蕾), XIAO Hao¹ (肖皓), YE Jia² (叶佳), MA Guohong^1* (马国红). Numerical Simulation of Radial Ultrasonic Assisted MIG Welding Arc[J]. J Shanghai Jiaotong Univ Sci, 2024, 29(2): 330-338.

参考文献

[1] YADAV S, DOUMANIDIS C. Thermomechanical analysis of an ultrasonic rapid manufacturing (URM) system [J]. Journal of Manufacturing Processes, 2005, 7(2): 153-161.
[2] LANGENECKER B. Effects of ultrasound on deformation characteristics of metals [J]. IEEE Transactions on Sonics and Ultrasonics, 1966, 13(1): 1-8.
[3] GALLEGO-JUAREZ J A, RODRIGUEZ G, ACOSTA V, et al. Power ultrasonic transducers with extensive radiators for industrial processing [J]. Ultrasonics Sonochemistry, 2010, 17(6): 953-964.
[4] SATPATHY M P, SAHOO S K. Microstructural and mechanical performance of ultrasonic spot welded AlCu joints for various surface conditions [J]. Journal of Manufacturing Processes, 2016, 22: 108-114.
[5] KUMAR A, KUMARESAN T, PANDIT A B, et al. Characterization of flow phenomena induced by ultrasonic horn [J]. Chemical Engineering Science, 2006, 61(22): 7410-7420.
[6] WU X, LIU T, CAI W. Microstructure, welding mechanism, and failure of Al/Cu ultrasonic welds [J]. Journal of Manufacturing Processes, 2015, 20: 321-331.
[7] XIE W F, HUANG T, YANG C L, et al. Comparison of microstructure, mechanical properties, and corrosion behavior of Gas Metal Arc (GMA) and Ultrasonicwave-assisted GMA (U-GMA) welded joints of Al-ZnMg alloy [J]. Journal of Materials Processing Technology, 2020, 277: 116470.
[8] NING F D, CONG W L. Ultrasonic vibration-assisted (UV-A) manufacturing processes: State of the art and future perspectives [J]. Journal of Manufacturing Processes, 2020, 51: 174-190.
[9] YANG Z C, ZHU L D, ZHANG G X, et al. Review of ultrasonic vibration-assisted machining in advanced materials [J]. International Journal of Machine Tools and Manufacture, 2020, 156: 103594.
[10] KUMAR S, WU C S, PADHY G K, et al. Application of ultrasonic vibrations in welding and metal processing: A status review [J]. Journal of Manufacturing Processes, 2017, 26: 295-322.
[11] ZHU Q, LEI Y C, WANG Y L, et al. Effects of arcultrasonic on pores distribution and tensile property in TIG welding joints of MGH956 alloy [J]. Fusion Engineering and Design, 2014, 89(12): 2964-2970.
[12] WANG Y J, YU C, LU H, et al. Research status and future perspectives on ultrasonic arc welding technique [J]. Journal of Manufacturing Processes, 2020, 58: 936-954.
[13] DA CUNHA T V, BOHORQUEZ C E N. Ultrasound in arc welding: A review [J]. Ultrasonics, 2015, 56: 201-209.
[14] THAVAMANI R, BALUSAMY V, NAMPOOTHIRI J, et al. Mitigation of hot cracking in Inconel 718 superalloy by ultrasonic vibration during gas tungsten arc welding [J]. Journal of Alloys and Compounds, 2018, 740: 870-878.
[15] XIE W F, FAN C L, YANG C L, et al. Effect of acoustic field parameters on arc acoustic binding during ultrasonic wave-assisted arc welding [J]. Ultrasonics Sonochemistry, 2016, 29: 476-484.
[16] HUA C, LU H, YU C, et al. Reduction of ductility-dip cracking susceptibility by ultrasonic-assisted GTAW [J]. Journal of Materials Processing Technology, 2017, 239: 240-250.
[17] FAN Y Y, YANG C L, LIN S B, et al. Ultrasonic wave assisted GMAW [J]. Welding Journal, 2012, 91(3): 91- 99.
[18] CHEN C, FAN C L, CAI X Y, et al. Microstructure and mechanical properties of Q235 steel welded joint in pulsed and un-pulsed ultrasonic assisted gas tungsten arc welding [J]. Journal of Materials Processing Technology, 2020, 275: 116335.
[19] CHEN C, FAN C L, CAI X Y, et al. Arc characteristics and weld appearance in pulsed ultrasonic assisted GTAW process [J]. Results in Physics, 2019, 15: 102692.
[20] BAEVA M, KOZAKOV R, GORCHAKOV S, et al. Two-temperature chemically non-equilibrium modelling of transferred arcs [J]. Plasma Sources Science and Technology, 2012, 21(5): 055027.
[21] LUO J, YAO Z X, XUE K L. Anti-gravity gradient unique arc behavior in the longitudinal electric magnetic field hybrid tungsten inert gas arc welding [J]. The International Journal of Advanced Manufacturing Technology, 2016, 84(1/2/3/4): 647-661.
[22] OGINO Y, HIRATA Y, MURPHY A B. Numerical simulation of GMAW process using Ar and an Ar-CO2 gas mixture [J]. Welding in the World, 2016, 60(2): 345-353.
[23] GAO X S, WU C S, GOECKE S F, et al. Numerical simulation of temperature field, fluid flow and weld bead formation in oscillating single mode laser-GMA hybrid welding [J]. Journal of Materials Processing Technology, 2017, 242: 147-159.
[24] WANG D Q, HUA C, LU H. Numerical analysis of ultrasonic waves in the gas tungsten arc welding(GTAW) with ultrasonic excitation of current [J]. International Journal of Heat and Mass Transfer, 2020, 158: 119847.
[25] HSU K C, ETEMADI K, PFENDER E. Study of the free-burning high-intensity argon arc [J]. Journal of Applied Physics, 1983, 54(3): 1293-1301.

径向超声波辅助MIG焊电弧的数值模拟

Numerical Simulation of Radial Ultrasonic Assisted MIG Welding Arc

PDF (PC)

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 1

编辑推荐

Metrics

本文评价