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Melting efficiency calculation of “finite-element-modeled” weld-bead and “experimental” weld-bead for laser-irradiated Hastelloy C-276 sheet

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Abstract

The cross-sectional geometry of the weld bead, which is associated with the maximum utilization of input energy, has been determined in the present work. In this respect, finite element analysis (FEA) has been implemented to generate five different weld bead shapes at around a similar peak temperature of 1700 °C to simulate laser beam welding of Hastelloy C-276 sheet through the bead-on-plate (BOP) method. Variations in the volumetric heat-source model, process parameters, and bead geometries led to varying melting efficiency. Three methods were implemented for the calculation of the melting efficiency associated with different bead geometries. The melting efficiency of bead geometries was found to be in the order: cylindrical shape > dowel pin shape > conical shape > tack nail shape > semi-circular shape. The melting efficiency was found to drop with the increment in the linear heat input. The analysis of the heat flux (HFL) vector showed that the inclination of the maximum heat flux vector with the welding direction is an important factor in determining the melting efficiency.

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Acknowledgements

The authors are grateful to all the faculty members, technical staff, and research scholars of the Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, for extending their support in carrying out various experiments. The authors are grateful to the financial support from the Department of Science and Technology, Ministry of Science and Technology, Government of India, under the FIST Program-2007 (SR/FIST/ETII-031/2007) and the Ministry of Human Resource Development and Department of Heavy Industries, Government of India, under the IMPRINT Program-2017 for Project-6917. The authors want to extend their sincere thanks to Mr. Roshan Kumar Naik, a Research scholar of the Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, for extending his needful support in the ABAQUS software analysis.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, West Bengal, 721302, Kharagpur, India

    Kalinga Simant Bal & Asimava Roy Choudhury

  2. Department of Mechanical Engineering, National Institute of Technology Raipur, Chhattisgarh, 492010, India

    Kalinga Simant Bal

  3. Department of Metallurgical & Materials Engineering, Indian Institute of Technology Kharagpur, West Bengal, 721302, Kharagpur, India

    Jyotsna Dutta Majumdar

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  1. Kalinga Simant Bal
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Highlights

• Melting efficiency = f (incident power, welding speed, bead geometry).

• Inclination of HFL vectors ⇒ heat flux distribution during the welding.

• Change of heat flux distribution from 3D to 2D » increase in energy absorption.

Recommended for publication by Commission IV—Power Beam Processes.

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Bal, K.S., Dutta Majumdar, J. & Roy Choudhury, A. Melting efficiency calculation of “finite-element-modeled” weld-bead and “experimental” weld-bead for laser-irradiated Hastelloy C-276 sheet. Weld World 67, 1509–1526 (2023). https://doi.org/10.1007/s40194-023-01515-5

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