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Numerical modeling of heat transfer and fluid flow in hybrid laser–TIG welding of aluminum alloy AA6082

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Abstract

This paper describes a three-dimensional numerical model based on finite volume method to simulate heat transfer and fluid flow in laser–tungsten inert gas (TIG) hybrid welding process. To simplify the model and reduce the calculation time, keyhole dynamics are not considered; instead, a new modified volumetric heat source model is presented for the laser source to take into account the effect of the keyhole on the heat transfer into the workpiece. Due to the presence of arc current, an appropriate electromagnetic model based on the Maxwell equations are also solved to calculate electromagnetic forces in the weld pool. The results of computer simulation, including temperature, current density, electromagnetic, and melted material velocity field, are presented here. Furthermore, several dimensionless numbers are employed to recognize the importance of fluid flow driving forces in the weld pool. It is deduced that the fluid flow has an important effect on the weld pool shape. It is also founded that among the driving forces, Marangoni force is dominant fluid force in the weld pool. Besides, calculated results of hybrid welding process are compared with those of TIG and laser welding processes. The weld pool depth is relatively the same, but the width of the weld pool is highly larger in hybrid welding than lone laser welding. Eventually, the presented model is validated by comparison between calculated and experimental weld pool shape. It is founded that there is a good agreement as the capability of this model can be proved.

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Authors and Affiliations

  1. School of Metallurgy and Materials Engineering, Iran University of Science and Technology, Tehran, Iran

    Amir Hossein Faraji, Massoud Goodarzi & Seyed Hossein Seyedein

  2. CR ENEA Casaccia, Rome, Italy

    Giuseppe Barbieri

  3. Department of Mechanical Engineering, University of Calabria, Arcavacata Rende, CS, Italy

    Carmine Maletta

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  1. Amir Hossein Faraji
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  2. Massoud Goodarzi
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  3. Seyed Hossein Seyedein
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  4. Giuseppe Barbieri
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  5. Carmine Maletta
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Correspondence to Amir Hossein Faraji.

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Faraji, A.H., Goodarzi, M., Seyedein, S.H. et al. Numerical modeling of heat transfer and fluid flow in hybrid laser–TIG welding of aluminum alloy AA6082. Int J Adv Manuf Technol 77, 2067–2082 (2015). https://doi.org/10.1007/s00170-014-6589-6

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