Finite element modeling of an alternating current ... · Finite element modeling of an alternating current electromagnetic weld pool support in full penetration laser beam welding
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J. Laser Appl. 28, 022404 (2016); https://doi.org/10.2351/1.4943906 28, 022404
Finite element modeling of an alternatingcurrent electromagnetic weld pool supportin full penetration laser beam welding ofthick duplex stainless steel platesCite as: J. Laser Appl. 28, 022404 (2016); https://doi.org/10.2351/1.4943906Submitted: 29 February 2016 . Accepted: 01 March 2016 . Published Online: 31 March 2016
Marcel Bachmann, Richard Kunze, Vjaceslav Avilov, and Michael Rethmeier
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Finite element modeling of an alternating current electromagnetic weld poolsupport in full penetration laser beam welding of thick duplex stainless steelplates
Marcel BachmannBAM Federal Institute for Materials Research and Testing, Unter den Eichen 87, 12205 Berlin, Germany
Richard Kunze and Vjaceslav AvilovTechnical University Berlin, Institute of Machine Tools and Factory Management, Pascalstraße 8–9,10587 Berlin, Germany
Michael RethmeierBAM Federal Institute for Materials Research and Testing, Unter den Eichen 87, 12205 Berlin, Germany andTechnical University Berlin, Institute of Machine Tools and Factory Management, Pascalstraße 8–9,10587 Berlin, Germany
(Received 29 February 2016; accepted for publication 1 March 2016; published 31 March 2016)
An electromagnetic weld pool support system for 20 mm thick duplex stainless steel AISI 2205
was investigated numerically and compared to experiments. In our former publications, it was
shown how an alternating current (AC) magnetic field below the process zone directed
perpendicular to the welding direction can induce vertically directed Lorentz forces. These can
counteract the gravitational forces and allow for a suppression of material drop-out for austenitic
stainless steels and aluminum alloys. In this investigation, we additionally adopted a steady-state
complex magnetic permeability model for the consideration of the magnetic hysteresis behavior
due to the ferritic characteristics of the material. The model was calibrated against the
Jiles–Atherton model. The material model was also successfully tested against an experimental
configuration before welding with a 30 mm diameter cylinder of austenitic stainless steel sur-
rounded by duplex stainless steel. Thereby, the effects of the Curie temperature on the magnetic
characteristics in the vicinity of the later welding zone were simulated. The welding process was
modeled with a three-dimensional turbulent steady-state model including heat transfer and fluid dy-
namics as well as the electromagnetic field equations. Main physical effects, the thermo-capillary
(Marangoni) convection at the weld pool boundaries, the natural convection due to gravity as well
as latent heat of solid–liquid phase transitions at the phase boundaries were accounted for in the
model. The feedback of the electromagnetic forces on the weld pool was described in terms of the
electromagnetic-induced pressure. The finite element software COMSOL Multiphysics 4.2 was
used in this investigation. It is shown that the gravity drop-out associated with the welding of
20 mm thick duplex stainless steel plates due to the hydrostatic pressure can be prevented by the
application of AC magnetic fields between around 70 and 90 mT. The corresponding oscillation
frequencies were between 1 and 10 kHz and the electromagnetic AC powers were between 1 and
2.3 kW. In the experiments, values of the electromagnetic AC power between 1.6 and 2.4 kW at os-
cillation frequencies between 1.2 and 2.5 kHz were found to be optimal to avoid melt sagging or
drop-out of melt in single pass full-penetration laser beam welding of 15 and 20 mm thick AISI
2205. VC 2016 Laser Institute of America. [http://dx.doi.org/10.2351/1.4943906]
7M. Bachmann, V. Avilov, A. Gumenyuk, and M. Rethmeier,
“Experimental and numerical investigation of an electromagnetic weld
pool support system for high power laser beam welding of austenitic stain-
less steel,” J. Mater. Process. Technol. 214, 578–591 (2014).8A. Backhouse, Welding of Austenitic & Duplex Stainless Steels—Overview(Outokumpu Stainless, 2011); available at www.scottish-enterprise.com/~/
stainless-steels-overview-backhouse-outokumpu.pdf.9D. C. Jiles and D. L. Atherton, “Theory of ferromagnetic hysteresis,”
J. Magn. Magn. Mater. 61, 48–60 (1986).10N. C. Pop and O. F. Caltun, “Jiles-Atherton magnetic hysteresis parame-
ters identification,” Acta Phys. Pol., A 120, 491–496 (2011).11S. S. M. Tavares, M. R. Da Silva, and J. M. Neto, “Magnetic property
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Compd. 313, 168–173 (2000).12COMSOL Multiphysics, Modeling Hysteresis Effects, 2008.13T. A. Palmer, J. W. Elmer, and S. S. Babu, “Observations of ferrite/austen-
ite transforma-tions in the heat affected zone of 2205 duplex stainless steel
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307–321 (2004).14V. Avilov, A. Fritzsche, M. Bachmann, A. Gumenyuk, and M. Rethmeier,
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Meet the Authors
Dr.-Ing. Marcel Bachmann, born 1984 in Berlin, is with
the BAM Federal Institute for Materials Research and
Testing in Berlin, Germany, in the “Welding Technology”
department since 2009. He received his diploma from the
Technical University Berlin in Physical Engineering and his
Ph.D. for numerical investigations of electromagnetically
assisted high power laser beam welding processes.
Currently, he is working on several projects involving nu-
merical simulations in welding processes.
Mr. Kunze was with the BAM Federal Institute for
Materials Research and Testing in the “Welding
Technology” department. Currently, he is working on his
master thesis in Information Technology in Mechanical
Engineering to be received from the Technical University
Berlin. His thesis deals with multiphysical numerical simula-
tions in laser beam welding.
Dr. rer. nat. Vjaceslav Avilov is with the Institute of
Machine Tools and Factory Management at the Technical
University Berlin. Before, he was with the BAM Federal
Institute for Materials Research and Testing. His current
activities include experimental work on electromagnetic-
assisted high power laser beam as well as electron beam
welding processes.
Professor Dr.-Ing. Michael Rethmeier is with the BAM
Federal Institute for Materials Research and Testing. He is
the head of the “Welding Technology” division. He is also
heading the “Chair of Safety of Joined Components” at the
Institute of Machine Tools and Factory Management,
Technical University Berlin. Present research topics include
amongst others innovative arc welding processes, high
power laser beam welding and numerical simulations in vari-
ous welding processes.
J. Laser Appl., Vol. 28, No. 2, May 2016 Bachmann et al. 022404-9