• International Journal of Naval Architecture and Ocean Engineering
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• v.5 no.3
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• pp.348-363
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• 2013

The use of I-Core sandwich panel has increased in cruise ship deck structure since it can provide similar bending strength with conventional stiffened plate while keeping lighter weight and lower web height. However, due to its thin plate thickness, i.e. about 4~6 mm at most, it is assembled by high power $CO_2$ laser welding to minimize the welding deformation. This research proposes a volumetric heat source model for T-joint of the I-Core sandwich panel and a method to use shell element model for a thermal elasto-plastic analysis to predict welding deformation. This paper, Part I, focuses on the heat source model. A circular cone type heat source model is newly suggested in heat transfer analysis to realize similar melting zone with that observed in experiment. An additional suggestion is made to consider negative defocus, which is commonly applied in T-joint laser welding since it can provide deeper penetration than zero defocus. The proposed heat source is also verified through 3D thermal elasto-plastic analysis to compare welding deformation with experimental results. A parametric study for different welding speeds, defocus values, and welding powers is performed to investigate the effect on the melting zone and welding deformation. In Part II, focuses on the proposed method to employ shell element model to predict welding deformation in thermal elasto-plastic analysis instead of solid element model.

• Journal of Welding and Joining
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• v.19 no.1
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• pp.104-111
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• 2001

This study presents an analysis method for heat flow and deformation of sheet metal laser welding. A heat source model for 2-dimensional heat flow analysis of laser welding process was suggested in this paper. To investigate the availability of the heat source model, the analysis results were compared and estimated with the results of previous researches. We could get a good agreement between the results of numerical analysis and experiments in the temperature distribution of weldment. Due to the characteristics of welding process, some kinds of deformations are usually generated in a welded structure. Generally, the degree of deformation is dependent on the welding sequence constraints as well as input power Therefore, in this paper we evaluate the deformation of gas pressure vessel according to the welding sequence and input power. In the analysis of weld deformation, 2-dimensional thermo-elasto-plastic analysis was performed for the gas pressure vessel by using a commercial FE program package.

• Journal of Mechanical Science and Technology
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• v.16 no.9
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• pp.1054-1064
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• 2002

Numerical prediction of welding-induced residual stresses using the finite element method has been a common practice in the development or refinement of welded product designs. Various researchers have studied several thermal models associated with the welding process. Among these thermal models, ramp heat input and double-ellipsoid moving source have been investigated. These heat-source models predict the temperature fields and history with or without accuracy. However, these models can predict the thermal characteristics of the welding process that influence the formation of the inherent plastic strains, which ultimately determines the final state of residual stresses in the weldment. The magnitude and distribution of residual stresses are compared. Although the two models predict similar magnitude of the longitudinal stress, the double-ellipsoid moving source model predicts wider tensile stress zones than the other one. And, both the ramp heating and moving source models predict the stress results in reasonable agreement with the experimental data.

• Journal of Welding and Joining
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• v.33 no.6
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• pp.60-66
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• 2015

Molten zone shape of pulse laser welding is affected by welding conditions such as beam power, beam speed, irradiation time, pulse frequency, etc. and is divided into conduction type and keyhole type. It is necessary to design heat source model for irradiation of laser beam in the pulse laser welding. Shape variables and the maximum energy density value of the heat source model are different depending on the molten zone shape. In this paper, pulse laser welding simulation for joining of cylindrical part and circular cover was carried out. The heat source model for pulse laser beam with circular path was applied to the heat input boundary condition, radiative and conductive heat transfer were considered for the thermal boundary condition. For each phase, thermal and mechanical properties according to temperature were also applied to analysis. Analytical results were in good agreement with the molten zone size of specimen under the same welding conditions. So, the reliability of the welding simulation was verified. Finally, the improvements for reducing residual deformation after cover welding could be reviewed analytically.

• Proceedings of the KWS Conference
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• 2003.11a
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• pp.36-38
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• 2003

In order to understand the basic knowledge on the model of heat source in hybrid welding, authors have conducted finite element analysis to calculate heat distribution using three heat source models of non-split type and split type(Volume, Volume-Volume, Volume-Surface). From the research result, we can confirm that Volume-Volume heat source of split type is suitable for the analysis of heat distribution.

• Journal of Welding and Joining
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• v.31 no.4
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• pp.62-66
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• 2013

Overlay welding is carried out to improve the corrosion resistance, wear resistance and heat resistance on the surface of the chemical plant and steelmaking plant structures. In overlay welding, control of the bead size and the temperature distribution of weldment are particularly important because that is directly connected to the improvement of quality and productivity. The aim of this study is to model the welding heat source that is very useful to analyze the bead size and temperature distribution of weldment. To find the welding heat source model, numerical analyses are performed by using FE software MSC-marc.

• Journal of Welding and Joining
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• v.23 no.1
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• pp.55-60
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• 2005

A three-dimensional Gaussian heat source model is modified to include the effects of the gap and thickness-difference for the laser keyhole welding. The gap of the butt joint influences the welding efficiency such that the melting area decreases linearly with the gap. When the different plate thickness is used such as the tailored blank welding, melting areas of the thick and thin plates are predicted by introducing the thickness-difference factor. The calculated results using the modified heat source show reasonably good agreements with the experimental results.

• Journal of the Society of Naval Architects of Korea
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• v.44 no.6
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• pp.598-604
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• 2007

The purpose of this study is to establish the predictive method of welding distortion and residual stress for the channel I butt SA (submerged arc) weldment using FEA. In order to do it, the heat input model for the weldment was defined as the combined heat source with the surface heat flux of gaussian distribution and volumetric heat source uniformly distributed within weld groove by comparing the shapes of molten pool and temperature distribution obtained by FEA with those of experiments. The arc efficiency of SA welding for two-dimensional FE analysis was evaluated as 0.85. The welding distortion and residual stress of the weldment obtained by FEA and heat input model proposed have a good agreement with those obtained by experiment. Based on the results, it was suggested that the proper heat input model should be required to evaluate the welding distortion for weldment.

• Journal of Welding and Joining
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• v.18 no.4
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• pp.76-81
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• 2000

In this research, various heat source equations that have been proposed in previous study were calculated and compared with new model in various laser parameters. This is to treat the problem of predicting, by numerical analysis, the thermo-mechanical behaviors of laser spot welding for thin stainless steel plates. A finite element code, ABAQUS is used for the heat transfer analysis with a three-dimensional plane assumption. Experimental studies if the laser spot welding have also bee conducted to validate the numerical models presented. The results suggest that temperature profiles and weld dimensions are varied according to the heat source of the laser beam. For this reason, it is essential to incorporate an accurate description of the heat source.

• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2006.11a
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• pp.189-192
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• 2006

The purpose of this study is to evaluate the welding distortion at the channel I butt SA weldment. In order to do it, the heat input model for the weldment was defined as combined heat source with the surface heat flux of gaussian mode and volume heat source uniformly distributed within weld groove on the basis of comparing the shapes of molten pool and temperature distribution obtained by FEA and experiment. The arc efficiency of SA welding for 2 dimensional FE analysis was determined as 0.85. The results of welding distortions at the weldment obtained by FEA and heat input conditions proposed have a good agreement with those obtained by experiment. Based on the results, it was suggested that the proper heat input model should be required to evaluate the welding distortion for weldment.