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Metals
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Application of Numerical Simulation in Welding
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Application of Numerical Simulation in Welding

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (30 December 2019) | Viewed by 26505

Special Issue Editor

Prof. Dr. António Bastos Pereira

E-Mail Website1 Website2
Guest Editor
Centre for Mechanical Technology and Automation, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal
Interests: adhesive joints; adhesive strength; mechanical testing; manufacturing processes; welding
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Many advanced structural applications require the joining of materials. Typical applications include stiffened panels for aircraft interiors, parts of car bodies, or electronic components.

Today, welding arises as a possibility, which is extraordinarily fast, secure and precise when compared to the use of adhesives, rivets, or bolts. In several cases, welding is the less expensive process of connection. The laser (Light Amplification Stimulated by Emission of Radiation) is one of the most promising welding processes, in conjunction with, for example, friction welding.

Despite the progress achieved, there are significant obstacles to the generalization of laser welding, not only in terms of high equipment costs but also due to the complexity of mechanical behavior after welding. In fact, there is currently no sufficiently deep knowledge of the weldability, defects and ruin, especially with regard to, for example, the 3rd generation of advanced high strength steels, the welding of thermoplastic composites or new processes like 3D printing of metals by laser.

This Special Issue is focused on the numerical simulation of the welding processes, e.g., using finite element method, computational fluid dynamic modelling, among other tools.

Prof. António Pereira
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Welding simulation
  • Laser welding
  • Friction stir welding
  • Strength of welded joints
  • Additive manufacturing of metals

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Published Papers (4 papers)

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Research

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15 pages, 3153 KiB  
Article
A Study on the Influences of Welding Position on the Keyhole and Molten Pool Behavior in Laser Welding of a Titanium Alloy
by Baohua Chang, Zhang Yuan, Hao Cheng, Haigang Li, Dong Du and Jiguo Shan
Metals 2019, 9(10), 1082; https://doi.org/10.3390/met9101082 - 8 Oct 2019
Cited by 8 | Viewed by 5963
Abstract
Various welding positions need be used in laser welding of structures with complex configurations. Therefore, it is necessary to gain knowledge of how the welding positions can influence the keyhole and weld pool behavior in order to better control the laser weld quality. [...] Read more.
Various welding positions need be used in laser welding of structures with complex configurations. Therefore, it is necessary to gain knowledge of how the welding positions can influence the keyhole and weld pool behavior in order to better control the laser weld quality. In the present study, a computational fluid mechanics (CFD) model was constructed to simulate the laser-welding process of the titanium alloy Ti6Al4V, with which the keyhole stability and the fluid flow characteristics in weld pool were studied for four welding positions, i.e., flat welding, horizontal welding, vertical-up welding, and vertical-down welding. Results showed that the stability of the keyhole was the best in flat welding, the worst in horizontal welding, and moderate in vertical welding positions. Increasing heat input (the ratio of laser power to welding speed) could increase the keyhole stability. When the small heat input was used, the dimensions and flow patterns of weld pools were similar for different welding positions. When the heat input was increased, the weld pool size was increased, and the fluid flow in the weld pool became turbulent. The influences of gravity became significant when a large heat input was used, especially for laser welding with vertical positions. Too high a heat input in vertical-up laser welding would lead to oscillation and separation of molten metal around the keyhole, and in turn result in burn-through holes in the laser weld. Based on the present study, moderate heat input was suggested in positional laser welding to generate a stable keyhole and, meanwhile, to guarantee good weld quality. Full article
(This article belongs to the Special Issue Application of Numerical Simulation in Welding)
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14 pages, 6029 KiB  
Article
Numerical Simulation for FSW Process at Welding Aluminium Alloy AA6082-T6
by Nikola Sibalic and Milan Vukcevic
Metals 2019, 9(7), 747; https://doi.org/10.3390/met9070747 - 3 Jul 2019
Cited by 13 | Viewed by 6532
Abstract
This paper presents the numerical simulation of the Friction stir welding (FSW) process obtained by using the DEFORM 3D software package. Numerical simulations are based on experimental research, welding of aluminum alloy AA6082-T6 by FSW method, which has the thickness of 7.8 mm. [...] Read more.
This paper presents the numerical simulation of the Friction stir welding (FSW) process obtained by using the DEFORM 3D software package. Numerical simulations are based on experimental research, welding of aluminum alloy AA6082-T6 by FSW method, which has the thickness of 7.8 mm. The aim of this paper is to determine the reliability of numerical simulations in the FSW process, which is followed by large deformations, where influential geometric and kinematic parameters are varied. Numerical research was done on the basis of the adopted five-phase orthogonal experimental plan with a variety of factors on two levels and repetition at the central point of the plan for four times. The parameters varied in the experiment are: Welding speed v mm/min, a rotation speed of tool ω rpm, angle of pin slopes α o, a diameter of the pin d mm, diameter of the shoulder D mm. During the performing of the FSW process, forces were measured in three normal directions: Axial force Fz, longitudinal force Fx and side force Fy, as well as the temperature in the adopted measuring positions of the workpiece. The experimental results obtained in this way were compared with the numerical experiment in the same adopted measuring positions, i.e., in the paper an analysis and comparison of the obtained experimental and numerical data of the measured forces and the generated temperature field were made. Full article
(This article belongs to the Special Issue Application of Numerical Simulation in Welding)
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15 pages, 3123 KiB  
Article
Numerical Simulation Analysis of Dual-Beam Laser Welding of Tailored Blanks with Different Thicknesses
by Xinge Zhang, Liqun Li, Yanbin Chen, Xiaocui Zhu and Shijun Ji
Metals 2019, 9(2), 135; https://doi.org/10.3390/met9020135 - 26 Jan 2019
Cited by 17 | Viewed by 4370
Abstract
In order to meet the requirements of alignment capability, gap tolerance and welding track control, dual-beam laser welding has been put forward to weld tailored blanks with different thicknesses. The arrangement mode and power ratio of dual-beam laser determine the heat transfer and [...] Read more.
In order to meet the requirements of alignment capability, gap tolerance and welding track control, dual-beam laser welding has been put forward to weld tailored blanks with different thicknesses. The arrangement mode and power ratio of dual-beam laser determine the heat transfer and temperature field distribution, and then influence the weld profile and weld quality. In this study, based on consideration of the temperature dependence of material physical properties, convection and radiation heat transfer, and material latent heat, the finite element model was developed. The model validated was conducted to compare with experimental results and it showed good agreement. The arrangement mode and power ratio of dual-beam laser welding were compared and optimized based on the consideration of the weld width on top surface and gap tolerance. Finally, the temperature field characteristics with the preferable process were analyzed in detail according to the numerical simulation. The calculated results indicated the weld width is mainly controlled by the laser irradiation on the thin plate, and dual-beam laser welding of tailored blanks has great advantages on improving heat transfer, weld profile and gap tolerance, which helps to reduce welding defects and enhance welding quality. Full article
(This article belongs to the Special Issue Application of Numerical Simulation in Welding)
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Review

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19 pages, 1380 KiB  
Review
Comparison of Finite Element Methods in Fusion Welding Processes—A Review
by Eva S. V. Marques, Francisco J. G. Silva and António B. Pereira
Metals 2020, 10(1), 75; https://doi.org/10.3390/met10010075 - 2 Jan 2020
Cited by 46 | Viewed by 8918
Abstract
Currently, welding processes have become one of the most used methods for joining materials in all kinds of industries, thanks to properties such as high speed and high tensile strength. However, despite these advantages, this type of connection method has some drawbacks, for [...] Read more.
Currently, welding processes have become one of the most used methods for joining materials in all kinds of industries, thanks to properties such as high speed and high tensile strength. However, despite these advantages, this type of connection method has some drawbacks, for example, residual stress and structural distortion, mainly due to the process thermal cycles. Structural distortion is one of the major concerns of industrial joining practice. In order to decrease distortion, the variation of welding sequence, direction, and clamping conditions, have been applied through several years, by trial and error tests. However, numerical simulation enables virtual examination of the welding, mainly due to the progress on the numerical methods, which stimulated the research on welding simulation models. These models can cover a wide spectrum of physical and thermal processes occurring during, and after welding. The aim of this paper is to provide wider information about types of finite element method (FEM) in fusion welding processes and to demonstrate the accuracy of FEM models results compared to experimental. Full article
(This article belongs to the Special Issue Application of Numerical Simulation in Welding)
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