Modelling of the Thermal History During Submerged Arc Welding and Wire and Arc Additive Manufacturing

Abstract

The finite element method (FEM) and finite element analysis (FEA) are numerical techniques to solve partial differential and ordinary differential equations. They are widely used in engineering, physics, and other fields. The development of these FEM and FEA makes it possible to accurately simulate the temperature history of many processes, such as welding and additive manufacturing process. In this work, a general-purpose finite element analysis (FEA) software, ABAQUS, was used to predict the temperature profile on the welding line for submerged arc welding (SAW) and wire and arc additive manufacturing (WAAM) processes. A new technology called Additive Manufacturing Modeler was utilized within ABAQUS to enhance the accuracy of the simulation. The peak temperature and cooling rates can be determined with the temperature profile, which is crucial for understanding and optimizing the welding and additive manufacturing processes. Using the 3D model in ABAQUS also makes it possible to know the temperatures at any time and at any point on the plate. This allows for a more comprehensive process analysis. Additionally, the bead widths and depths during the processes can therefore be predicted, which can be used to control the final geometry of the product. Finally, the predicted results from the ABAQUS model were compared with experimental data taken under similar conditions. For the SAW process, the results were compared with the research done by Lecoanet [1], who made measurements using thermocouples. The thermal history on the welding line and also in the heat-affected zone are analyzed and compared. As for the WAAM process, the results are compared with McDonald's [2] work, where the temperature profile on the welding line and also the solidification cooling rates were analyzed and compared. The penetration of the bead is also compared. The results from the model showed good agreement with the experimental data, validating the simulation's accuracy. The work demonstrates the applicability of using the Additive Manufacturing Modeler technology within ABAQUS for predicting temperature profiles and other process parameters in welding and additive manufacturing.