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Uncertainty analysis of a water flow calorimeter while welding in short-circuit and spray transfer regimes

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Abstract

The thermal efficiency of arc welding influences the cooling rate, peak temperature, and microstructures of a weld, which affects the material properties of the welded joint. This work quantifies the uncertainty of thermal efficiency measurements on gas metal arc welds using low (2.5 kW) and high (9.5 kW) arc powers. In order to understand the effect of calorimeter parameters on the measured efficiency, a two-factor, two-level full factorial design was carried out for each arc power condition. In this study, the factors are flow rate (2 l/min and 5 l/min) and plate thickness (0.25 in. [6.35 mm] and 0.375 in. [9.53 mm]). The results show that the uncertainty in the thermal efficiency measurements increases when both higher flow rates and plate thickness are used. Moreover, the use of a thick plate causes the heat transfer regime to change, increasing the cooling rate and decreasing the observed thermal efficiency. Uncertainty is also influenced by the metal transfer mode during welding.

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Acknowledgments

The authors would like to thank the Centre for Advanced Materials Joining (CAMJ) in the University of Waterloo where all the experiments were performed. Additionally, Mr. P. D. C. Assunção would like to acknowledge the Coordination for the Improvement of Higher Education Personnel (CAPES) from the Brazilian Ministry of Education for a scholarship to visit the University of Waterloo.

Funding

This research study was funded by the TC Energy, Inc.

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Authors and Affiliations

  1. Centre for Advanced Materials Joining (CAMJ), University of Waterloo, 200 University Avenue West, Waterloo, ON, N2L 3G1, Canada

    R. A. Ribeiro & A. P. Gerlich

  2. Liburdi Automation Inc. - Liburdi GAPCO, 400 ON-6, Dundas, ON, L9H 7K4, Canada

    E. B. F. Dos Santos

  3. Metallic Materials Characterization Laboratory (LCAM), Federal University of Pará (UFPA), Rua Augusto Corrêa, 1 - Guamá, Belém, PA, 66075-110, Brazil

    P. D. C. Assunção

  4. Waterloo Laboratory for Inverse Analysis and Thermal Sciences (WatLIT), University of Waterloo, 200 University Avenue West, Waterloo, ON, N2L 3G1, Canada

    K. J. Daun

Authors
  1. R. A. Ribeiro
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  2. E. B. F. Dos Santos
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  3. P. D. C. Assunção
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  4. K. J. Daun
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  5. A. P. Gerlich
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Correspondence to R. A. Ribeiro.

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Ribeiro, R.A., Dos Santos, E.B.F., Assunção, P.D.C. et al. Uncertainty analysis of a water flow calorimeter while welding in short-circuit and spray transfer regimes. Weld World 64, 1615–1624 (2020). https://doi.org/10.1007/s40194-020-00931-1

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  • DOI: https://doi.org/10.1007/s40194-020-00931-1

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