Numerical simulation on MIG arc brazing-fusion welding of aluminum alloy to galvanized steel plate
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Based on the difference in melting point between aluminum alloy and steel, metal inert gas (MIG) arc brazing-fusion welding process was developed to join thin 6013 aluminum alloy plate to galvanized steel plate. A finite element model for lap joint was established to study its thermal process. In modeling, MIG arc was treated as the double ellipse Gaussian plane heat source and the overheated metal droplet was considered as the uniform body heat source. The effects of the zinc coating and the overlap gap were taken into consideration. The brazed seam width and the width of heat-affected zinc coating on the back side of galvanized steel plate were used to validate the calculated results. The results show that the calculated results are in good agreement with experimental results. The calculation results indicate that the temperature is not uniformly distributed in the brazing-fusion welded joint. There is a great difference in the reaction temperature and time at different positions on the brazed interface. In order to satisfy the energy condition in which aluminum plate is fully penetrated and steel plate is not melted, a corresponding relationship that the welding current and welding speed are synchronized to be increased must be followed.
KeywordsBrazing-fusion welding Dissimilar joint Pulsed MIG welding Numerical simulation Finite element method Energy condition
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