Heat and Fluid Flow Modeling in Twin-Wire Welding

Parre, M D and Sharma, Abhay and Eswaran, Vinayak (2011) Heat and Fluid Flow Modeling in Twin-Wire Welding. Masters thesis, Indian Institute of Technology Hyderabad.

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Abstract

Twin-wire welding is a metal joining process that uses two electrodes to generate localized heat at the weld joint. Due to the effect of magnetic arc blow, both of the arcs direct towards each other and subsequently act as a single heat source. This heat source is basically a double-ellipsoidal moving heat source that follows Gaussian distribution. It causes melting of the specimen and formation of weld-pool. Numerical simulation of this entire phenomenon is a classical problem based on Gaussian distributed double-ellipsoidal moving heat source with fluid flow driven by Electro Magnetic Force (EMF), buoyancy, surface tension, marangoni stress and gravity. Three-dimensional physical model of the specimen is modeled using ANSYS-WORKBENCH environment. This model is imported into commercial Computational Fluid Dynamics (CFD) solver ANSYS-FLUENT 12.0.1, which is based on Finite Volume Method (FVM) of discretization to solve the governing equations, initial and boundary conditions. The present work aims at developing the heat and fluid flow model for twin-wire welding process over the previous work based on steady state heat conduction alone. It investigates the effectiveness of previous model and suggests suitable modification in flux compensation factor that accounts for cooling time. This work correlates the process parameters like wire- diameter, current and polarity with temperature distribution of the specimen, velocity of the flow in the weld pool and cooling time of the specimen.

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