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A simulation-aided least squares reconstruction scheme for the measurement of welding process heat flux distributions

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Abstract

A new method for the measurement of two-dimensional heat flux profiles for GTAW processes is presented. The method is based on a least squares reconstruction algorithm for the inverse heat transfer problem for a steady-state temperature distribution in a specimen body. The temperature is measured with an experimental setup suited for the heat input of a welding process. The temperature distribution is then used to reconstruct the heat flux distribution on the specimen surface using a heat flux approach function. To calculate the temperature distribution ratio for the current approach heat flux profile, a numerical simulation model of the specimen is embedded in the reconstruction procedure. The residuum between the actual temperature distribution and the test function temperature is reduced using a least squares optimization step until convergence. The method is verified using a numerically calculated temperature distribution which is compared with a predefined heat flux profile. Moreover, the method is compared with a split-anode measurement for one-dimensional and two-dimensional reconstruction approaches. Measurements of a process with an inclined torch as well as a process with a magnetically deflected arc demonstrate the capability of the new method for the measurement of two-dimensionally resolved heat flux distributions of GTAW processes.

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Authors and Affiliations

  1. Technische Universität Dresden, Institute of Manufacturing Science and Engineering, George-Bähr-Str.3c, D-01069, Dresden, Germany

    M. Trautmann, M. Hertel, S. Jäckel & U. Füssel

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  1. M. Trautmann
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  2. M. Hertel
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  3. S. Jäckel
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  4. U. Füssel
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Correspondence to M. Trautmann.

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Recommended for publication by Study Group 212 - The Physics of Welding

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Trautmann, M., Hertel, M., Jäckel, S. et al. A simulation-aided least squares reconstruction scheme for the measurement of welding process heat flux distributions. Weld World 63, 1873–1882 (2019). https://doi.org/10.1007/s40194-019-00781-6

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  • DOI: https://doi.org/10.1007/s40194-019-00781-6

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