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Improved gas metal arc welding multi-physics process model and its application to MIL A46100 armor-grade steel butt-welds

M. Grujicic (Department of Mechanical Engineering, Clemson University, Clemson, South Carolina, USA)
J.S. Snipes (Department of Mechanical Engineering, Clemson University, Clemson, South Carolina, USA)
R. Galgalikar (Department of Mechanical Engineering, Clemson University, Clemson, South Carolina, USA)
S. Ramaswami (Department of Mechanical Engineering, Clemson University, Clemson, South Carolina, USA)
R. Yavari (Department of Mechanical Engineering, Clemson University, Clemson, South Carolina, USA)
C.-F. Yen (Army Research Laboratory, Survivability Materials Branch, Aberdeen Proving Ground, Aberdeen, Maryland, USA)
B.A. Cheeseman (Army Research Laboratory, Survivability Materials Branch, Aberdeen Proving Ground, Aberdeen, Maryland, USA)
J.S. Montgomery (Army Research Laboratory, Survivability Materials Branch, Aberdeen Proving Ground, Aberdeen, Maryland, USA)

Multidiscipline Modeling in Materials and Structures

ISSN: 1573-6105

Article publication date: 5 August 2014

181

Abstract

Purpose

The purpose of this paper is to develop multi-physics computational model for the conventional gas metal arc welding (GMAW) joining process has been improved with respect to its predictive capabilities regarding the spatial distribution of the mechanical properties (strength, in particular) within the weld.

Design/methodology/approach

The improved GMAW process model is next applied to the case of butt-welding of MIL A46100 (a prototypical high-hardness armor-grade martensitic steel) workpieces using filler-metal electrodes made of the same material. A critical assessment is conducted of the basic foundation of the model, including its five modules, each dedicated to handling a specific aspect of the GMAW process, i.e.: first, electro-dynamics of the welding-gun; second, radiation/convection controlled heat transfer from the electric arc to the workpiece and mass transfer from the filler-metal consumable electrode to the weld; third, prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; fourth, the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; and fifth, spatial distribution of the as-welded material mechanical properties.

Findings

The predictions of the improved GMAW process model pertaining to the spatial distribution of the material microstructure and properties within the MIL A46100 butt-weld are found to be consistent with general expectations and prior observations.

Originality/value

To explain microstructure/property relationships within different portions of the weld, advanced physical-metallurgy concepts and principles are identified, and their governing equations parameterized and applied within a post-processing data-reduction procedure.

Keywords

Citation

Grujicic, M., Snipes, J.S., Galgalikar, R., Ramaswami, S., Yavari, R., Yen, C.-.-F., Cheeseman, B.A. and Montgomery, J.S. (2014), "Improved gas metal arc welding multi-physics process model and its application to MIL A46100 armor-grade steel butt-welds", Multidiscipline Modeling in Materials and Structures, Vol. 10 No. 2, pp. 176-210. https://doi.org/10.1108/MMMS-05-2013-0038

Publisher

:

Emerald Group Publishing Limited

Copyright © 2014, Emerald Group Publishing Limited

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