*C Monterey, California
TD=
THESI
ELECT
JUL 2 84i9
THESIS
DETERMINATION OF GTA
WELDING EFFICIENCIES
by
CANDONINO P. FRANCHE
MARCH 1993
93- 16842
UNCLASSIFIED
SECURITY CLASSIFICATION OF THIS PAGE
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NAVAL POSTGRADUATE SCHOOL (Ifapplicable) NAVAL POSTGRADUATE SCHOOL
ME
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MONTERY,CA 93943-50 MONTEREY,CA 93943-5000
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ORGANIZATION Ifff applicable)
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13a. TYPE OF REPORT 13b. TIME COVERED 14. DATE OF REPORT (year, month, day) 15. PAGE COUNT
Masters Thesis in M.E. From: March 1992 To: March 1993 1993March25 74
16. SUPPLEMENTARY NOTATION
The views expressed in this thesis are those of the author and do not reflect the official policy or position of the Department of Defense or the U.S.
Government.
17. COSATI CODES 1B. SUBJECT TERMS (continueon reverse if necessaryandidentify by block number)
FIELD GROUP SUBGROUP Laser Arc Welding, Solidification Parameters, Numerical Methods, Determining
Welding Efficiencies.
Determination of GTA
Welding Efficiencies
by
Candonino P. Franche
Lieutenant, United States Navy
B.S.M.E. FEATI University, Philippines, 1974
M.B.A., National University, San Diego, CA., 1990
Submitted in partial fulfillment
of the requirements for the degree of
from the
Authors:
Candonint/P. ?Ynche
ii
ABSTRACT
A method is developed for estimating welding efficiencies for moving arc GTAW processes.
Under quasi-steady conditions, the net heat transfer rate from the weld pool to the workpiece is
estimated from a 3-D numerical heat transfer conduction model. The dimensions of the weld pool
used in the computational model are obtained experimentally using a laser vision system and by
metallurgical examination. The welding efficiency is then calculated by dividing the net heat transfer
rate by the total power input during the experiments. Efficiencies are measured for a range of power
inputs and torch speeds and then compared with those available in the literature.
Accesion For
NTIS CRA&I
DTIC TAE,
U ..al::.Oj; :•d -
By .................
.......................
Av,•Y~h!',1y C,,E~s
Ava":; . or
Dist
Siii .
TABLE OF CONTENTS
I. INTRODUCTION ................... 1
iv
A. ESTIMATING WELDING EFFICIENCY ........... .. 38
V
LIST OF FIGURES
vi
Figure 17. Gas Tungsten Arc Welding (GTAW) Process
Showing the Reference and Moving Coordinate
System ........... ................... ... 30
Figure 18. Grid Network used in the Computations.. 35
vii
Figure 28. (a) Longitudinal Temperature Contour, (b)
Traverse Temperature Contour, and (c) Metal
Cross Section for Run *13 ............. ... 51
Figure 29. (a) Longitudinal Temperature Contour, (b)
Traverse Temperature Contour, and (c) Metal
Cross Section for Run #18 ............. ... 52
Figure 30. (a) Longitudinal Temperature Contour, (b)
Traverse Temperature Contour, and (c) Metal
Cross Section for Run #24 ............. ... 53
Figure 31. (a) Longitudinal Temperature Contour, (b)
Traverse Temperature Contour, and (c) Metal
viii
LIST OF TABLES
ix
ACKNOWLEDGEUENTS
x
1. INTRODUCTION
1
tungsten
electrode
losses
losses ,
arc
,•/ Heat
workpiece *"' ý AffectedI
Z
Zone
2
transfer rate to the workpiece and the power dissipation from
the source:
Q/EI
where: Q = heat rate transferred to the
workpiece
O=
[x Ux
2a.9K ( 2as
UR /2n (TT) KG
exp -U(R-x)]
Q= 2ae
2n (T-TO) KR
where:
T = Temperature of the point in question
To= Initial Temperature at the point in
question
3
assumed to be constant
Ko= Modified Bessel Function of the second
kind and zero order, and
R = Distance from the point in question to the
heat source.
The above equations have been used extensively by researchers
but the methodology has drawbacks because Rosenthal's
4
during GTA welding using the cathode-anode theory. They
assumed the electrode to be the cathode and the workpiece
(water cooled) to be the anode. The number of electrons were
postulated to be proportional to the rate of heat transfer to
the anode. Welding efficiencies were computed based on
gathered measurements of heat transfer to the anode for an arc
of zero length. Increasing the arc length decreased overall
efficiency of the arc due to convection and radiation. They
reported efficiencies with this type of technique from 80 to
90%. Malmuth et al. [Ref. 13] and Tsai and Eager [Ref. 141
used the same technique and reported values ranging from 83 to
90% by varying the current input.
Other calorimetric measurements have also been reported by
Giedt et al [Ref. 15). The energy transfer to the workpiece
is determined by immersing the workpiece in liquid nitrogen
immediately after a weld is completed. The amount of liquid
vaporized gives the total thermal energy transferred to the
workpiece. Giedt et al. [Ref. 15] measured a mean welding arc
efficiency of 80%. Smartt et al. [Ref. 16] using the same
equipment measured welding arc efficiencies that ranged from
71-84%.
5
of the weld pool is determined experimentally during quasi-
NY
"a X
6
estimation of the welding efficiency. The efficiency is
computed by finding the net heat transfer rate into the parent
material from the weld pool boundary. In the following, the
experimental and the numerical techniques employed are
described in detail.
7
II. EXPERIMENTAL APPARATUS, MATERIALS, AND PROCEDURES
8
GAS TUNGSTEN ARC WELDING
PROCESS (SCHEMATIC)
ARGON
POWER SOURCE
WELDING DIRECTION +
CONTACT TUBE :
(CATHODE )Il , GAS
SHIELDING
TUNGSTEN
ELECTRODE -- ARC
WELD IN\X~"x
POOL
BASE "WELD
METAL (ANODE) DEPOSIT
9
Table I. CMNMACAL COMPOSITION OF HY-80 STEEL.
ELEMKENT PERCENT
Phosphorus 0.025
Sulfur 0.025
Silicon 0.15 - 0.35
Titanium 0.02
Vanadium 0.03
Copper 0.25
10
failure. This steel is manufactured with specification of MIL-
S-16216 (Ships).
11
COOLING WATEROURCEI
VACUUM P
PUMP
LSER
CAMERA
NITROGEN ____
HY-80 PLATE
MONrTOR
"LRECORDER
SYSTEM CONTROLLER
1. Laser Unit
The pulsed nitrogen laser is a PRA/Model UV12
manufactured by PRA Laser Inc., Ontario, Canada. The optical
laser radiation has an operating wavelength of 337 nm (near-
visible ultraviolet region in the spectrum) with 3 ns duration
12
laser requires an external vacuum pump that is capable of
maintaining 60 torr [Ref. 20]. A nitrogen supply to the laser
is continuously maintained at 275 - 315 milliliter/second (35-
40 cubic feet/hour). Figure 5 and 6 are the photographs of
the laser and the vacuum pump respectively.
13
Figure 6. Vacuum Pump, Manufactured by Bosch, Inc.
2. Camera Unit
14
Figure 7. Camera Unit.
barrel. Figure 8 shows the camera set up with the torch and
the workpiece. The camera unit is controlled by the system
controller to which it is connected via fiber optic cable.
3. System Controller
The system controller is manufactured by Control
Vision System, Idaho Falls, Idaho. It can be regulated to
send the appropriate trigger commands to pulse the laser and
initiate shuttering of the camera unit. Electronic delay
15
Figure 8. Camera Unit, Torch, and Weldpiece Set-up.
between the laser and the shutter unit required the setting of
the shutter delay of .38 As. The controller provides power to
the camera unit and serve for manual adjustments of the
16
Figure ).TV Monitor, System Controller, and VHS
Recorder.
17
5. Welding Equipment
18
firmly hold the tungsten electrode and to transmit the welding
19
D. EXPERIMENTAL PROCEDURE
20
settings of 240, 200, 175, and 150 Amps and three welding
21
POWER VS. WELD POOL DEPTH
4-i 100
I z_
4 h/
3 I
22
POWER VS. WELD POOL DEPTH
6 -a-SPEED 1.693 mm/sec 0
o-'
5A
- /
0/
//
0 E
_I a-a
U-i
3
2500 3000 3500 4000 4500
' IN I /
POWER (WATTS)
23
POWER VS. WELD POOL DEPTH
7-]
6+
CE
U-i
-1
44 I I "
24
POWER VS. WELD POOL DEPTH
7 --9- SPEED 2.127 mm/sec
-a--SPEED 1.693 mmfsec
-o--SPEED 1.269 mm/sec,
6
0 E
S-i yZ'• /
01 E
4 %a -' /
3 I
25
Table 11. SMIMARY OF WELDING SETTINGS AND WELD POOL
MMURMUMTS WITH SPEND OF 2.127 vm/sec.
Power Amps Volts Weld Pool Weld Pool Weld Pool length
(Watts) (:k4) (t.3) Width Depth Ahead Behind
(mm) (mm) (mm) (mm)
26
Table III. ,,URMlARY OF WELDING SETTINGS AND WELD POOL
S WITH SPEED OF 1.693 -- /sec.
27
Table IV. SU3AIRY OF WELDING SETTINGS AND WELD POOL
MEASUREMEmTS WITH SPEED OF 1.269 mm/sec.
28
Ill. COMPUTATIONS OF W;3LDING EFFICIENCY
since the weld pool location, shape, size, and the temperature
to the torch. Under this assumption, the heat input from the
heat source to the weld pool is equal to the net heat transfer
the weld pool shape and size (based on experimental data) and
set the weld pool boundary at the melting temperature Tm, the
values (i.e., lengths forward (al) and behind the arc (a2),
weld pool width (b), and weld pool depth (c) are needed for
29
experimental runs as described in the previous chapter. The
frames.
HEAT
SOUIC E
TORCH
SVELOCITY, U
WORKPIECEZ ,
30
apT a k aT+ a kaT)a kaT
p T) --- + - (-)•c - + 2- (-L-- ý) +source Eq (1)
-
ax' ( C (x'- ay C ay az Oz
X=x-Ut:orcht Eq (2)
ax _ ax I
at at
or,
U U!'- Ut ..
b Eq (3)
axa-•(¢x"'Z't))a, ax
x, ax
ax (4 (x, y, z, t)
ax x YZ(((XIyIzt))) Eq (5)
ax' ax ax
31
a 4¢(xtyZ, t) + (U(x,y,z, t) ) t))
q((x,y,z,
B. BOUNDARY CONDITIONS
kaT
x=0; h(Tf-T)=-k-!
32
XXL; ax
x~,;h (Tt-T) =k-L
axx
z ZL
Top :
Bottom (Insulated) :
y=O;
ay
At the weld pool boundary and its interior: T = Tm
="~~~' ilI i ay
where :
h = heat transfer coefficient
33
Tf= ambient fluid temperature
E = emissivity
a = Stefan Boltzman constant
k = thermal conductivity of the solid
Tm= melting temperature of the solid
C. NUMERICAL SOLUTION
34
condition was reached. The rectangular domain was discretized
into a fine mesh grading as shown in Figure 18. The grading
near the heat source is on the order of .5 mm by .5 mm by .5
mm. Outside the heat source, a non-uniform grid is employed.
35
900....
800
500
S600
1
Cn u rve fitI
500 0 McGannon
4~00 1 .. . 5 .
36
LEGEND
IRON
S....H AISI 347 SS
?-8O...............
•- -- - ------- -- -- - -
------------ - - "
.... o..... .. .. .. . .. .. .. .. .
CQ.. .....
37
IV. RESULTS AND DISCUSSION
38
Table VI. SUMMARY OF GTA WELDING EFFICIENCY MEASUREMENTS
WITH SPEED 2.127 mm/Sec.
Run # Input Power Total Heat Input Efficiency
(W) (w) (%)
1 3925 2590 66
2 3906 2601 67
3 3875 2407 62
4 3500 2289 65
5 3323 2471 74
6 3306 2241 68
7 3062 2080 68
8 3016 2092 69
9 2969 2115 71
10 2806 2116 75
11 2181 1888 70
12 2649 1864 70
39
Table VII. SMU•ARY OF GTA WELD EFFICIENCY JEASUR•M•NTS
WITH WELDING SPEED OF 1.693 mm/sec.
Run # Input Power Total Beat Input Efficiency
13 4347 2849 66
14 4239 3084 73
15 3945 2846 72
16 3715 2518 68
17 3533 2702 76
18 3416 2448 72
19 3124 2123 68
20 3036 2230 73
21 2948 2191 74
22 2731 2029 74
23 2710 2101 78
24 2622 1894 72
40
Table VIII. SUMMARY OF GTA WELD EFFICIENCY MEASUREMENTS
WITH WELDING SPEED OF 1.269 =m/sec.
Run # Input Power Total Heat Input Efficiency
(J) (W) (%)
25 4082 2542 62
26 3993 2525 63
27 3956 2638 67
28 3603 2672 74
29 3518 2716 77
30 3420 2710 79
31 3016 2202 73
32 2946 2503 85
33 2853 2420 85
34 2749 2031 74
35 2657 1923 72
36 2635 2115 80
41
POWER VS. EFFICIENCY
80-
-:5--SPEED 2.127 mm/sec
j- /
z_ 70
LL.
LIU
-i
60
42
POWER VS. EFFICIENCY
80
-a--SPEED 1.693 mm/sec
70 \
6/
O%...LLI'707//j,
U- //
-ii
60-n
2500 3000 3500 4000 4500
44 POWER (WATTS)
43
POWER VS. EFFICIENCY
90
80 -
z ,7
LU. "70-
+\
~1
- 1 V.
60
2500 3000 3500 4000 4500
POWER (WATTS)
44
iI I2 II I II
B. TEMPERATURE CONTOURS
Based on the heat conduction model developed, the effects
45
reason behind this is that near the edge, heat transfer from
the source is not as efficient as when the torch moves further
away, allowing heat conduction in all directions within the
metal.
46
POWER VS. EFFICIENCY
90
--5--SPEED 2.127 mm/sec
ISPEED 1.693 mm/see
-o--SPEED 1.269 mm/sec
80 /
, / \/ .
LI.
oD
0-0v
S0
60
47
WELDING SPEED =2.127 mmlsec
DIRECTION OF TORCH
0.024 -2
o~o)0
0.022
0.021Go8
0.0124
0020.01 0.02 0.03 0.04 0.05 0.0600
(a) LONGITUDINAL TEMPERATURE CONTOUR
0.024-
0.022- Ww 0
0.02-
o~ t~
48.
WELDING SPEED.= 2.127 mmlsec
DIRECTION OF TORCH
0.024- 140 200
0.022 Nm
uv-
0.02-0 -
0.0180.0O-O
0.0164
0.024
0.01 0.02 0.03 0.04 0.05 0.06 0.07
49
WELDING SPEED =2.127 mmlsec
DIRECTION OF TORCH
0.024-N; ) 20
0.02-
0.018
0.016-
0.014
0.0n- -- 26
0.06 0.02 0.03 0&04 0.05 0.08 0.07
0.01e 4o:Zz2z
0.016-
0.014
44
50
WELDING SPEED =1.693 mm/sec
DIRECTION OF TORCH
0.024-
00.=24
00.022
0.016-0.0120
0.0.014
240020
0.006 000.0 .01 000.0 O.0N
.2 0.056 0417
0 0
0.02- 4 80wo540
WELDING SPEED-= 1.693 mm/sec
DIRECTION OF TORCH
0.024- 6
0.=01402
0.02- o
0.018 0
0.016-
0.014 _____________
0.012
0.01 0.02 0.03 0.04 0.OS 0.06 0.07
52
WELDING SPEED =1.693 mm/sec
DIRECTION OF TORCH
0.022- 00 140 00
0.02- /
0.01e - 2
0.016-
0.014
0.012.
0.01 0.02 0.;3 0.04 0.05 0.06 0.0'7
M -
0.14
-. 4 t
53
WELDING SPEED =1.269 mmlsec
DIRECTION OF TORCH
0.024 -4W o
0.02-10
0.018-
0.016-
o
0.014
0.012.
0.01 0.02 0.03 0.04 0.05 0.06 0.0?
(a) LONGITUDINAL TEMPERATURE CONTOUR
0.024- 460 462002
0.022-
0.02 -6So
0.018-
0.(" 0 0
0.0141
0.012 - -
0.006 0.011 0.016 0021 0.026 00ý31 0036 0.041
54
WELDING SPEED =1.269 mmlsec
DIRECTION OF TORCH
0.024- Z 1 6
800 4000
0.022-
0.02-
0.018
0.016
0.014 400
0.012-1 0.200w00 0
0.01 00 .300 050.06 00
0.016 - w200
0.014 400 400
0.012.
0.006 0.011 0.016 0.021 0.02 0.031 0.036 0.041
74 -
55
WELDING SPEED.= 1.269 mmlsec
DIRECTION OF TORCH
0..024 ( 62001
0.022 400 000
0.021 o
0.018 -
0.019-~
0.014-
0.012 - -
0.01 0.02 0.03 0.04 0.05 0.06 0.07
0.018-
0.0141
0-
56
(a) (b) (C)
57
T= 0 SEC T=1 SEC T=2 SEC
58
V. CONCLUSIONS AND RECOMMEDATIONS
59
LIST OF REFERENCES
1. U.S. Patent 419,032, Jan. 7, 1890, "Methods of Welding by
Electricity, " Charles Lewis Coffin, Detroit, Mich.
2. Rosenthal, D., and Schmerber, R., "Thermal Study of Arc
Welding - Experimental Verification of Theoretical
Formulas," Welding Journal, 17, April 1938, pp.2 -8.
3. Rosenthal, D., "Mathematical Theory of Heat Distribution
During Welding and Cutting," Welding Journal, 20, May
1941, pp. 220s-234s.
4. Rosenthal, D., "The Theory of Moving Sources of Heat and
Its Application to Metal Treatments," Trans. ASME, 68,
Nov 1946, pp. 849-866.
5. Kou, S., Welding Metallurgy, John Wiley & Sons, 1987.
60
14. Tsai, N.S., and Eager, T.W., "Distribution of the Heat
and Current Fluxes and Gas Tungsten Arcs," Metallurgical
Transactions B, vol. 16B(4), 841-846, 1985.
15. Giedt, W.H., Tallerico, L.N., and Fuerschbach, P.W., GTA
Welding Efficiency: Calometric and Temperature Field
Measurements, Welding Journal, vol. 68(1), 28-32, 1989.
16. Smartt, H.B., Stewart, J.A., and Einerson, C.J., Heat
Transfer in Gas Tungsten Arc Welding, ASM
Metals/Materials Series, 8511-011, 1-14, 1986.
17. Goldak, J., Chakravarti, A., and Bibby, M., "A Finite
Element Model for Welding Heat Sources," Metallurgical
Transactions, Volume 15B, June 1984, pp 299-305.
18. Carry,H.B.:Modern Welding Technology, Prentice-Hall,
Englewood Cliffs, NJ, 1979.
61
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