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Processes
Special Issues
Modeling and Simulation of Welding Processes
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Modeling and Simulation of Welding Processes

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (15 December 2022) | Viewed by 3505

Special Issue Editors

Dr. Chunming Lin

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Guest Editor
Department of Mechanical Engineering, Minghsin University of Science and Technology, Hsinchu 30401, Taiwan
Interests: welding metallurgy; lightweight structural designs for aircraft and automotive applications; the microstructure and mechanisms underlying novel alloy materials; the design and implementation of composite materials; the development of product design such as orthopedic implants and surgical instruments
Special Issues, Collections and Topics in MDPI journals
Dr. Huei-Sen Wang

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Guest Editor
Department of Materials Science and Engineering, I-Shou Universtiy, Kaohsiung City 84001, Taiwan
Interests: welding technology and metallurgy; metal material manufacturing technology
Prof. Dr. Ching-Min Cheng

E-Mail Website
Guest Editor
Department of Mechatronic Engineering, National Taiwan Normal University, Taipei City 106, Taiwan
Interests: welding metallurgy; welding engineering; materials science and engineering; metal forming

Special Issue Information

Dear Colleagues,

Recent advancements in welding and related materials joining technologies have enhanced the integrity and performance of assembled components and have led to the development of advanced manufacturing methods. Although advanced welding has been developed for several decades now, significant and exciting innovations often arise from both the process and/or material side, which provide an opportunity to solve many engineering problems.

Another key area of interest is related to welding metallurgy: The microstructural changes induced by welding and joining techniques can drastically modify the joints mechanical behavior. For that reason, it is necessary to correlate process parameters, microstructure, and mechanical response in welded joints. Finally, simulation and modeling of the thermomechanical behavior during welding and the predictions of existing phases due to the weld thermal cycle are critical to optimizing welding parameters.

For this Special Issue, papers on advanced welding for laser welding, friction stir welding, electron beam welding, arc welding, and hybrid welding are welcome. Publishing research on the effects of advanced welding on the material for microstructure and performance; development of process parameters for new advanced materials (high entropy alloys, light metal alloys, and dissimilar metals); modeling and simulation of welds process/material interaction, thermal effects, stresses, and distortion; and destructive and non-destructive control. Papers that combine both experimental and theoretical approaches are especially welcomed.

Contributions from around the world will contribute to the success of this Special Issue, which aims at spreading the potential of advanced welding at joining well-established and innovative metallic parts.

Dr. Chunming Lin
Dr. Huei-Sen Wang
Prof. Dr. Ching-Min Cheng
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • advanced welding
  • welding metallurgy
  • dissimilar weld
  • evolution of microstructure
  • properties in welds
  • modeling and simulation of welds process/material interaction
  • simulation of welding processes

Published Papers (2 papers)

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Research

15 pages, 4229 KiB  
Article
Chemical Behaviour of Copper in the Application of Unconstrained Cr-Ni-Al-Cu Metal Powders in Submerged Arc Welding: Gas Phase Thermodynamics and 3D Slag SEM Evidence
by Theresa Coetsee and Frederik De Bruin
Processes 2023, 11(2), 351; https://doi.org/10.3390/pr11020351 - 21 Jan 2023
Cited by 4 | Viewed by 1333
Abstract
Unconstrained metal powders of Cu, Cr, Ni and Al were applied to submerged arc welding (SAW) to clarify the chemical behaviour of copper in this modified SAW process. Aluminium metal is avoided in SAW because it is easily oxidised. Excessive aluminium oxides in [...] Read more.
Unconstrained metal powders of Cu, Cr, Ni and Al were applied to submerged arc welding (SAW) to clarify the chemical behaviour of copper in this modified SAW process. Aluminium metal is avoided in SAW because it is easily oxidised. Excessive aluminium oxides in the form of slag or inclusions in the weld metal will lead to poor weld metal materials properties. Aluminium is an effective deoxidiser and can be used to prevent Cr and Ni loss to the slag by preventing oxidation of these metals. The results show that carbon steel was alloyed to 5.3% Cr, 5.3% Ni, 3.6% Al and 5.2% Cu at 80% Cr yield, 81% Ni yield, 54% Al yield and 79% Cu yield. BSE (backscattered electron) images of the three-dimensional (3D) post-weld slag sample show 3D structures within the slag dome. The 3D structures contain features of vapour formation and recondensation. In addition, nano-strands appear in the 3D structures and confirm the vaporisation and recondensation of fluorides. The chemical behaviour of copper metal powder added in SAW is to vaporise as metallic copper and incorporate in the Al-Si-Mg-Ca-Mn-Fe-Cu-Na-Cr-Ni fluoride. Copper, in combination with aluminium, has a stabiliser effect in SAW due to its formation of an initial alloy melt of low liquidus temperature, thus decreasing the temperature required to melt high-melting-point metals such as Cr into the weld pool. Although Al and Cu have similar vapour pressures at specific temperatures, it appears that Cu does not substitute for Al in the gas phase. Gas-slag-alloy thermochemical equilibrium calculations confirm the partial oxygen pressure lowering effect of aluminium and the vaporisation of copper as metallic copper with very little copper-fluoride species expected to form. The quantity of metallic copper vaporisation calculated in the gas-slag-alloy thermochemical equilibrium is much higher than the vaporisation quantity measured in welding. This may be due to recondensation of vaporised copper which is not accounted for in the equilibrium calculation at the set arc cavity temperature, as well as the effect of surface-active elements such as sulphur and oxygen in limiting the vaporisation reaction of copper. Full article
(This article belongs to the Special Issue Modeling and Simulation of Welding Processes)
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19 pages, 4840 KiB  
Article
Modification of Flux Oxygen Behaviour via Co-Cr-Al Unconstrained Metal Powder Additions in Submerged Arc Welding: Gas Phase Thermodynamics and 3D Slag SEM Evidence
by Theresa Coetsee and Frederik De Bruin
Processes 2022, 10(11), 2452; https://doi.org/10.3390/pr10112452 - 19 Nov 2022
Cited by 7 | Viewed by 1785
Abstract
Aluminium metal is avoided as main reactant in submerged arc welding (SAW) because it is easily oxidised in this process. Aluminium is an effective de-oxidiser and can be used to prevent Cr and Co loss to the slag by preventing oxidation of these [...] Read more.
Aluminium metal is avoided as main reactant in submerged arc welding (SAW) because it is easily oxidised in this process. Aluminium is an effective de-oxidiser and can be used to prevent Cr and Co loss to the slag by preventing oxidation of these metals. In our novel application of aluminium metal powder in SAW we demonstrate the modification of flux oxygen behaviour. The Co-Cr-Al-alloyed weld metal total oxygen content is decreased to 180 ppm O, compared to 499 ppm O in the weld metal from the original flux, welded without metal powder additions. The flux oxygen behaviour is modified by the added aluminium powder through the lowering of the original flux-induced partial oxygen pressure in the arc cavity and at the molten flux-weld pool interface. Carbon steel was alloyed to 5.9% Co, 6.3 % Cr and 5.1% Al at 81% Co yield, 87% Cr yield and 70% Al yield. Gas-slag-alloy thermochemical equilibrium calculations confirm the partial oxygen-pressure-lowering effect of aluminium. BSE (backscattered electron) images of the three-dimensional (3D) post-weld slag sample show dome structures which contain features of vapour formation and re-condensation. These features consist of small spheres (sized less than 10 μm) and smaller needle-shaped particles coalescing into a porous sphere. EDX analyses show that the spheres consist of Si-Na-K-Fe-Mn-Co-Cr oxy-fluoride and the needles consist of low oxygen Si-Al-Ca-Mg-Na-K-Fe-Mn-Co-Cr oxy-fluoride. The element distribution and speciation data from the EDX analyses confirm modification of the flux oxygen behaviour via aluminium powder addition in lowering the partial oxygen pressure, which in turn prevents oxidation of Cr and Co and minimise losses to the slag. Full article
(This article belongs to the Special Issue Modeling and Simulation of Welding Processes)
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