熔化极气体保护焊传热与传质过程的数值研究
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摘要
熔化极气体保护焊(GMAW)操作方便、生产效率高,被广泛应用于各工业领域的焊接生产中,包括汽车、航空、造船、国防、石油、电子等工业。随着生产自动化要求的提高,选择最佳的操作参数对获得安全、高效、高质量的焊接过程十分重要。本研究数值模拟了不同焊接条件下GMAW中的传热与传质现象,讨论了有关的物理机理。本研究首先利用流体体积法(VOF)和连续介质模型建立了二维非稳态的GMAW统一模型。该模型可用于预测GMAW焊接过程中瞬态的输运现象,包括等离子电弧的结构与变化,焊丝熔化、熔滴形成、脱离、过渡和射入到熔池内,以及熔池输运特性等。利用该二维模型研究了焊丝的熔化现象和合理送丝速度的确定,以及保护气体成分对等离子电弧特性和金属过渡的影响。另外,考虑熔滴过渡、重力、电磁力、电弧压力和表面张力等的作用,建立了三维数值模型预测了GMAW移动焊接过程中复杂的输运现象,以及焊接参数对焊缝表面波纹形成的影响。
送丝速度必须与焊丝熔化速度保持动态的平衡以获得稳定的焊接过程。由于与其它焊接参数强烈耦合、以及熔滴周期性过渡的影响,送丝速度的确定非常复杂。利用二维数学模型,分析了焊丝中的传热和熔化现象,以及送丝速度对焊接稳定性的影响；得到了不同条件(焊接电流和焊丝直径)下,可获得稳定焊接的送丝速度,计算结果与实验结果相吻合。研究表明,合理的送丝速度为一个窄幅的连续区域,在此范围内可获得稳定的焊接过程。焊丝熔化速度具有一定的自我调整能力,在一定范围内可随送丝速度动态调节,并与之相平衡。在这个区域之外,送丝速度太慢会使焊丝烧导电嘴,太快会伸入到熔池内。
利用二维模型,数值研究了在连续恒定电能输入和恒定电流强度下,保护气体成分对GMAW焊接过程中瞬态输运现象的影响。模拟了纯Ar,75%Ar+25%He,50%Ar+50%He和25%Ar+75%He气氛下的GMAW过程中电弧区和金属区内的输运现象。研究发现,在Ar保护气体中掺入He,对电弧参数的瞬态分布、熔滴形成和过渡过程、以及焊缝形状和熔深都有重要的影响。结果显示,不同保护气体的热物性(如电离能、电导率、导热系数、比热和粘性系数等)在高温下差别显著,因此其电离产生的电弧具有不同的特性。由于氦的电离能较高,因此,当保护气体中的氦含量增加时,电弧发生显著收缩,电弧的形状由喇叭口形变成锥形。纯Ar气氛下,沿工件表面的电弧压力呈高斯分布；在高氦气氛下,电弧压力不再呈高斯分布,其顶部较平而峰值减小。高氦气氛下,随着电弧的收缩,熔滴底部出现向上的电磁力,延长熔滴悬于焊丝上的时间。因此,形成了扁圆形的熔滴以及更低的过渡频率。预测结果与实验观察到的现象相一致。
利用三维模型预测了GMAW移动焊接过程中熔池内的速度、温度和浓度的分布及其动态特性,重点研究了各焊接参数对焊波特征的影响。本研究发现焊波形成的机理与熔池表面的振荡幅度和焊接凝固速率有关,得到了不同焊接参数(如焊接电流,熔滴的大小、过渡频率和射入速度,焊接速度等)对焊波形状、间距和高度的影响。计算结果显示,在高焊接电流下,熔滴尺寸变小,过渡频率和射入速度增大,导致熔池内剧烈的对流,凝固速度减小,从而形成更加细密的焊波。
该研究有助于理解GMAW焊接过程的机理,更好地选择GMAW焊接过程的送丝速度、保护气体成分以及其它焊接参数,以提高焊接生产的质量和效率,从而提高工业过程的生产效率,降低生产成本。
Gas metal arc welding (GMAW) has been applied for jointing of metal in broad industries due to its high productivity, simplicity and ease of use, such as automotive, aerospace, shipbuilding, defense, oil, MEMS, electronics and many other industries. With the increase of mechanization and automation, selection of optimum operating parameters of GMAW becomes increasingly essential for higher weld quality, productivity and safety. This study presents a numerical investigation on the heat and mass transfer occurring in GMAW under various welding conditions. A 2D comprehensive mathematical model employing the volume of fluid (VOF) technique and the continuum formulation is developed, coupling the transient processes of arc plasma's generation and change; droplet formation, detachment, and impingement onto the workpiece; and welding pool dynamics. This model is used to study the electrode melting phenomena and the determination of wire-feed-speed (WFS), and the roles of shielding gas compositions in arc plasma and metal transfer. Furthermore, by considering the combined effects of droplet impingement, gravity, electromagnetic force, plasma arc force and surface tension force, a 3D moving GMAW model is developed to predict the complex transport phenomena and their effect on the formation of ripples on the bead surface.
In GMAW, the consumable electrode wire must be continuously fed in such a speed that it balances the electrode melting rate in order to achieve a stable welding. Due to the strong interplay with the other welding variables and periodic oscillations induced by the formation and detachment of droplet, the determination of WFS is very complex. The 2D model is used to examine the thermal process and melting phenomena in moving electrode, and the influence of WFS on stability of welding process. Taking into account the effects of welding current and electrode diameter, the equilibrium WFS for stable welding processes under various conditions are presented. It is found that the electrode extension length fluctuates as a function of time in a narrow range in which the electrode melting can "self-adjust" itself leading to an equilibrium WFS for a stable welding; otherwise may lead to either the electrode burn-back or the electrode stick-onto the weld pool. The predicted equilibrium WFS are in good agreements with the published experimental data that were obtained through the trial-and-error procedure.
Based on the 2D model, the effects of shielding gas compositions on the transient transport phenomena occurring in GMAW of mild steel at a continuously constant electric energy or constant current were studied. The behaviors of plasma arc and metal transfer for GMAW operating in arcs of pure argon,75% Ar+25% He,50% Ar+50% He and 25%Ar+ 75% He are obtained. The results indicate that the arcs in various shielding gases behave very differently due to the significant difference in thermophysical properties, especially the ionization potential. With the more addition of helium content, results in 1) the change of plasma arc shape from bell-like to cone-like and 2) the change of arc pressure distribution along the workpiece surface from Gaussian-like to flat-top with decreasing peak value. In high helium arc, the arc becomes increasingly contracted and produces a more significant upward electromagnetic force near the cathode, leading to the dramatically distorted distributions of arc parameters. The increase of helium content and the resulting arc contraction induce an upward electromagnetic force at the bottom of the droplet that sustains the droplet at the electrode tip. Thus, the more oblate droplet and the longer droplet formation time are produced. The behaviors of the predicted droplet shape and detachment frequency are confirmed by the published results.
The 3D model is employed to predict the transient distributions of velocity, temperature and species, weld pool dynamics and surface rippling on the solidified weld bead during a GMAW process. It is found that the surface ripples are formed by the interplay between the up-and-down weld pool dynamics, caused mainly by the periodic droplet impingements, and the rate of weld pool solidification. The effects of various welding parameters, including the welding current, droplet size, droplet frequency, droplet impinging velocity, and travel speed on the pitch (distance between two ripples) and height of the ripple are investigated. At high weld current, the impingement of small droplets with very high frequency produces the strong weld pool convection and slow solidification rate, forming fine and dense ripples.
This study will help to provide a reliable and productive welding technology for a wide range of industrial applications. It will have a much broader impact and benefit as follows:1) the improved fundamental understanding of arc plasma and metal transfer in GMAW; 2) the significant advance in GMAW process with right selection of operating parameters, such as WFS, shielding gas composition and so on, and hence the innovation in metal-joining technique; 3) the advance the industrial productivity of producing high quality welding components, thereby reducing overall production costs.
送丝速度必须与焊丝熔化速度保持动态的平衡以获得稳定的焊接过程。由于与其它焊接参数强烈耦合、以及熔滴周期性过渡的影响,送丝速度的确定非常复杂。利用二维数学模型,分析了焊丝中的传热和熔化现象,以及送丝速度对焊接稳定性的影响；得到了不同条件(焊接电流和焊丝直径)下,可获得稳定焊接的送丝速度,计算结果与实验结果相吻合。研究表明,合理的送丝速度为一个窄幅的连续区域,在此范围内可获得稳定的焊接过程。焊丝熔化速度具有一定的自我调整能力,在一定范围内可随送丝速度动态调节,并与之相平衡。在这个区域之外,送丝速度太慢会使焊丝烧导电嘴,太快会伸入到熔池内。
利用二维模型,数值研究了在连续恒定电能输入和恒定电流强度下,保护气体成分对GMAW焊接过程中瞬态输运现象的影响。模拟了纯Ar,75%Ar+25%He,50%Ar+50%He和25%Ar+75%He气氛下的GMAW过程中电弧区和金属区内的输运现象。研究发现,在Ar保护气体中掺入He,对电弧参数的瞬态分布、熔滴形成和过渡过程、以及焊缝形状和熔深都有重要的影响。结果显示,不同保护气体的热物性(如电离能、电导率、导热系数、比热和粘性系数等)在高温下差别显著,因此其电离产生的电弧具有不同的特性。由于氦的电离能较高,因此,当保护气体中的氦含量增加时,电弧发生显著收缩,电弧的形状由喇叭口形变成锥形。纯Ar气氛下,沿工件表面的电弧压力呈高斯分布；在高氦气氛下,电弧压力不再呈高斯分布,其顶部较平而峰值减小。高氦气氛下,随着电弧的收缩,熔滴底部出现向上的电磁力,延长熔滴悬于焊丝上的时间。因此,形成了扁圆形的熔滴以及更低的过渡频率。预测结果与实验观察到的现象相一致。
利用三维模型预测了GMAW移动焊接过程中熔池内的速度、温度和浓度的分布及其动态特性,重点研究了各焊接参数对焊波特征的影响。本研究发现焊波形成的机理与熔池表面的振荡幅度和焊接凝固速率有关,得到了不同焊接参数(如焊接电流,熔滴的大小、过渡频率和射入速度,焊接速度等)对焊波形状、间距和高度的影响。计算结果显示,在高焊接电流下,熔滴尺寸变小,过渡频率和射入速度增大,导致熔池内剧烈的对流,凝固速度减小,从而形成更加细密的焊波。
该研究有助于理解GMAW焊接过程的机理,更好地选择GMAW焊接过程的送丝速度、保护气体成分以及其它焊接参数,以提高焊接生产的质量和效率,从而提高工业过程的生产效率,降低生产成本。
Gas metal arc welding (GMAW) has been applied for jointing of metal in broad industries due to its high productivity, simplicity and ease of use, such as automotive, aerospace, shipbuilding, defense, oil, MEMS, electronics and many other industries. With the increase of mechanization and automation, selection of optimum operating parameters of GMAW becomes increasingly essential for higher weld quality, productivity and safety. This study presents a numerical investigation on the heat and mass transfer occurring in GMAW under various welding conditions. A 2D comprehensive mathematical model employing the volume of fluid (VOF) technique and the continuum formulation is developed, coupling the transient processes of arc plasma's generation and change; droplet formation, detachment, and impingement onto the workpiece; and welding pool dynamics. This model is used to study the electrode melting phenomena and the determination of wire-feed-speed (WFS), and the roles of shielding gas compositions in arc plasma and metal transfer. Furthermore, by considering the combined effects of droplet impingement, gravity, electromagnetic force, plasma arc force and surface tension force, a 3D moving GMAW model is developed to predict the complex transport phenomena and their effect on the formation of ripples on the bead surface.
In GMAW, the consumable electrode wire must be continuously fed in such a speed that it balances the electrode melting rate in order to achieve a stable welding. Due to the strong interplay with the other welding variables and periodic oscillations induced by the formation and detachment of droplet, the determination of WFS is very complex. The 2D model is used to examine the thermal process and melting phenomena in moving electrode, and the influence of WFS on stability of welding process. Taking into account the effects of welding current and electrode diameter, the equilibrium WFS for stable welding processes under various conditions are presented. It is found that the electrode extension length fluctuates as a function of time in a narrow range in which the electrode melting can "self-adjust" itself leading to an equilibrium WFS for a stable welding; otherwise may lead to either the electrode burn-back or the electrode stick-onto the weld pool. The predicted equilibrium WFS are in good agreements with the published experimental data that were obtained through the trial-and-error procedure.
Based on the 2D model, the effects of shielding gas compositions on the transient transport phenomena occurring in GMAW of mild steel at a continuously constant electric energy or constant current were studied. The behaviors of plasma arc and metal transfer for GMAW operating in arcs of pure argon,75% Ar+25% He,50% Ar+50% He and 25%Ar+ 75% He are obtained. The results indicate that the arcs in various shielding gases behave very differently due to the significant difference in thermophysical properties, especially the ionization potential. With the more addition of helium content, results in 1) the change of plasma arc shape from bell-like to cone-like and 2) the change of arc pressure distribution along the workpiece surface from Gaussian-like to flat-top with decreasing peak value. In high helium arc, the arc becomes increasingly contracted and produces a more significant upward electromagnetic force near the cathode, leading to the dramatically distorted distributions of arc parameters. The increase of helium content and the resulting arc contraction induce an upward electromagnetic force at the bottom of the droplet that sustains the droplet at the electrode tip. Thus, the more oblate droplet and the longer droplet formation time are produced. The behaviors of the predicted droplet shape and detachment frequency are confirmed by the published results.
The 3D model is employed to predict the transient distributions of velocity, temperature and species, weld pool dynamics and surface rippling on the solidified weld bead during a GMAW process. It is found that the surface ripples are formed by the interplay between the up-and-down weld pool dynamics, caused mainly by the periodic droplet impingements, and the rate of weld pool solidification. The effects of various welding parameters, including the welding current, droplet size, droplet frequency, droplet impinging velocity, and travel speed on the pitch (distance between two ripples) and height of the ripple are investigated. At high weld current, the impingement of small droplets with very high frequency produces the strong weld pool convection and slow solidification rate, forming fine and dense ripples.
This study will help to provide a reliable and productive welding technology for a wide range of industrial applications. It will have a much broader impact and benefit as follows:1) the improved fundamental understanding of arc plasma and metal transfer in GMAW; 2) the significant advance in GMAW process with right selection of operating parameters, such as WFS, shielding gas composition and so on, and hence the innovation in metal-joining technique; 3) the advance the industrial productivity of producing high quality welding components, thereby reducing overall production costs.
引文
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