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Numerical Investigation on Molten Pool Dynamics and Defect Formation in Electron Beam Welding of Aluminum Alloy
Journal of Materials Engineering and Performance ( IF 2.3 ) Pub Date : 2020-09-16 , DOI: 10.1007/s11665-020-05111-2
Ziyou Yang , Yuchao Fang , Jingshan He

Penetration depth fluctuations and spiking defects, which appear almost simultaneously during partial penetration electron beam welding (EBW) of aluminum alloy, lead to weakened joint strength. In this study, a novel dynamic heat source model, which can be used to understand the coupling behavior between the electron beam and keyhole wall, is proposed to simulate the EBW process. While studying molten pool patterns, the formation mechanism of weld defects is also discussed in detail. In addition, a corresponding experimental test is carried out as verification. The weld bead profile and dimensions predicted by simulations agree well with the experimental data. The periodic oscillation of the molten pool is the root cause of the penetration depth fluctuations. The simulation results show that spiking defect formation has four crucial steps: keyhole collapse, liquid metal backfilling, cutting by the molten pool boundary and liquid metal backfilling. The findings from this work provide a fundamental understanding of the formation mechanism of the penetration depth fluctuations and spiking defects during EBW of aluminum alloy to improve the weld bead quality.



中文翻译:

铝合金电子束焊接熔池动力学及缺陷形成的数值研究

在铝合金的部分熔透电子束焊接(EBW)期间几乎同时出现的渗透深度波动和尖峰缺陷会导致接头强度减弱。在这项研究中,提出了一种新颖的动态热源模型,可以用来了解电子束与锁孔壁之间的耦合行为,以模拟EBW过程。在研究熔池模式的同时,还详细讨论了焊接缺陷的形成机理。另外,进行相应的实验测试作为验证。模拟预测的焊缝轮廓和尺寸与实验数据吻合良好。熔池的周期性振动是熔深深度波动的根本原因。仿真结果表明,尖峰缺陷的形成有四个关键步骤:锁孔塌陷,液态金属回填,熔池边界切割和液态金属回填。这项工作的发现提供了对铝合金EBW中熔深深度波动和尖峰缺陷形成机理的基本理解,从而改善了焊缝质量。

更新日期:2020-09-16
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