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Experimental Validation of a Numerical Method that Predicts the Size of the Heat Affected Zone. Optimization of the Welding Parameters by the Taguchi’s Method

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Abstract

This work outlines the experimental validation of a numerical method which determines the size of the heat affected zone (HAZ) in a low carbon steel plate using the gas metal arc welding technique. The welding parameters match between the experimental and numerical simulations. The later allows the calculation of the weld beads and temperature fields from which the size of the HAZ can be inferred. This size from numerical simulations compares quite well with the experimentally measured HAZ from the metal grain macrostructure. A relationship between the bead size and the thermal energy source parameters, defined by the Goldak’s double ellipsoid, is found. Finally, the size of the HAZ is optimized by Taguchi’s method, which make use of the signal-to-noise ratio and the analysis of variance to obtain the influence of the parameters on the size of HAZ. The numerical code can be used for other electric arc welding techniques as GTAW or FCAW.

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Abbreviations

ah, ch :

Ellipsoidal semi-axes (mm)

B:

Width of the low carbon steel to be simulated (m)

Cp :

Caloric capacity (J kg−1 K−1)

D:

Thickness of the low carbon steel plate to be simulated (m)

K:

Fourier conductivity (J m−1 s−1 K−1)

L:

Length of the low carbon steel plate to be simulated (m)

n:

Number of trials

P:

Power of the electric arc (W)

p value:

Is the probability of obtaining a test statistic result

To :

Initial temperature (ºC)

Tf :

Fusion temperature (ºC)

ua, uc :

Ellipsoidal non dimension heat source parameters

v s :

Welding speed (m/s)

Yij :

The measured value of quality characteristics

α:

Thermal diffusivity (m2/s)

ΔH:

Phase change enthalpy (J kg−1)

Δx:

Longitudinal direction to the movement (m)

Δy:

Perpendicular direction to the movement (m)

ρ:

Density (kg m−3)

ANOVA:

Variance analysis

EBW:

Electron beam welding

FCAW:

Flux cored arc welding

FSW:

Friction stir welding

GMAW:

Gas metal arc welding

GTAW:

Gas tungsten arc welding

HAZ:

Heat affected zone

Nd-Yag:

Neodymium-doped yttrium aluminium garnet

SAW:

Submerged arc welding

SMAW:

Shield metal arc welding

S/N:

Signal to noise ratio

TIG:

Tungsten inert gas

i, j :

Subscripts of finite differences equations

i th , j th :

Trials

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Authors and Affiliations

  1. Department of Applied Physics and Materials Engineering, ETSII, Technical University of Madrid, C/José Gutiérrez Abascal st, 2, 28006, Madrid, Spain

    José L. Meseguer-Valdenebro & Antonio Portoles

  2. University Centre of Defence at the Spanish Air Force Academy, MDE-UPCT, C/Coronel López Peña, s/n, Santiago de la Ribera, 30720, Murcia, Spain

    José Serna

  3. Department of Mechanical Engineering, Faculty of Engineering-TECNUN, University of Navarra, P. Manuel Lardizabal, 13, 20018, San Sebastián, Spain

    Manuel Estrems

  4. Regional Development Institute, Material Science and Engineering, University of Castilla-La Mancha, 02071, Albacete, Spain

    Valentín Miguel

  5. Faculty of Architecture and Building Engineering, Technical University of Cartagena, Cartagena, Spain

    Eusebio Martínez-Conesa

Authors
  1. José L. Meseguer-Valdenebro
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  2. José Serna
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  3. Antonio Portoles
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  4. Manuel Estrems
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  5. Valentín Miguel
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  6. Eusebio Martínez-Conesa
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Correspondence to José L. Meseguer-Valdenebro.

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Meseguer-Valdenebro, J.L., Serna, J., Portoles, A. et al. Experimental Validation of a Numerical Method that Predicts the Size of the Heat Affected Zone. Optimization of the Welding Parameters by the Taguchi’s Method. Trans Indian Inst Met 69, 783–791 (2016). https://doi.org/10.1007/s12666-015-0554-4

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  • DOI: https://doi.org/10.1007/s12666-015-0554-4

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