Thermal-Metallurgical-Mechanical Analysis of Weldment Based on the CFD Simulation

Abstract

A new method of numerical thermal-metallurgical-mechanical analysis was introduced in this paper. The CFD welding simulation is based on the mass and heat transfer analysis solving mass, momentum, and energy conservation equations along with the Volume of Fluid (VOF) method. The VOF method is employed to track the shape of the free surface. The arc and droplet heat source model with electromagnetic force and arc pressure model were used for the arc welding process. Next, the temperature history of CFD welding simulation was transferred to the FEM domain for thermal-metallurgical-mechanical analysis with CFD-FEM framework. The diffusion kinetics considered phase transformation model successfully predicted phase fraction and residual stress distribution of carbon steel weldment. By using the combination of suggested T-M-Me analysis method and CFD welding analysis, it is possible to reproduce a phenomenon closer to reality. Also, the recent CFD-based process analyses and results that can be extended to multi-physical analysis were briefly introduced. However, considerable assumptions and simplified models are different from real welding phenomena. To solve this gap and to use welding simulation as a prediction tool rather than a reproduction, many young researchers will need to challenge.