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Simulation of wire metal transfer in the cold metal transfer (CMT) variant of gas metal arc welding using the smoothed particle hydrodynamics (SPH) approach


Oleg Mokrov, Sergej Warkentin, Lukas Westhofen, Stefan Rhys Jeske, Jan Bender, Rahul Sharma, Uwe Reisgen
Materials Science and Engineering Technology
pubimg

Cold metal transfer (CMT) is a variant of gas metal arc welding (GMAW) in which the molten metal of the wire is transferred to the weld pool mainly in the short-circuit phase. A special feature here is that the wire is retracted during this strongly controlled welding process. This allows precise and spatter-free formation of the weld seams with lower energy input. To simulate this process, a model based on the particle-based smoothed particle hydrodynamics (SPH) method is developed. This method provides a native solution for the mass and heat transfer. A simplified surrogate model was implemented as an arc heat source for welding simulation. This welding simulation model based on smoothed particle hydrodynamics method was augmented with surface effects, the Joule heating of the wire, and the effect of the electromagnetic forces. The model of metal transfer in the cold metal transfer process shows good qualitative agreement with real experiments.

» Show BibTeX

@article{MWW+24,
author = {Mokrov, O. and Warkentin, S. and Westhofen, L. and Jeske, S. and Bender, J. and Sharma, R. and Reisgen, U.},
title = {Simulation of wire metal transfer in the cold metal transfer (CMT) variant of gas metal arc welding using the smoothed particle hydrodynamics (SPH) approach},
journal = {Materialwissenschaft und Werkstofftechnik},
volume = {55},
number = {1},
pages = {62-71},
keywords = {cold metal transfer (CMT), free surface deformation, gas metal arc welding (GMAW), simulation, smoothed particle hydrodynamics (SPH), geglätteter Partikel-basierter hydrodynamischer Ansatz (SPH), Kaltmetalltransfer (CMT), Metallschutzgasschweißens, Oberflächenverformung, Simulation},
doi = {https://doi.org/10.1002/mawe.202300166},
year = {2024}
}





Ray tracing method with implicit surface detection for smoothed particle hydrodynamics-based laser beam welding simulations


Lukas Westhofen, Jan Kruska, Jan Bender, Sergej Warkentin, Oleg Mokrov, Rahul Sharma, Uwe Reisgen
Materials Science and Engineering Technology
pubimg

An important prerequisite for process simulations of laser beam welding is the accurate depiction of the surface energy distribution. This requires capturing the optical effects of the laser beam occurring at the free surface. In this work, a novel optics ray tracing scheme is proposed which can handle the reflection and absorption dynamics associated with laser beam welding. Showcasing the applicability of the approach, it is coupled with a novel surface detection algorithm based on smoothed particle hydrodynamics (SPH), which offers significant performance benefits over reconstruction-based methods. The results are compared to state-of-the-art experimental results in laser beam welding, for which an excellent correspondence in the case of the energy distributions inside capillaries is shown.

» Show BibTeX

@article{WKB+24,
author = {Westhofen, L. and Kruska, J. and Bender, J. and Warkentin, S. and Mokrov, O. and Sharma, R. and Reisgen, U.},
title = {Ray tracing method with implicit surface detection for smoothed particle hydrodynamics-based laser beam welding simulations},
journal = {Materialwissenschaft und Werkstofftechnik},
volume = {55},
number = {1},
pages = {40-52},
keywords = {heat transfer, hydrodynamics, laser beam welding, ray optics, ray tracing, smoothed particle, geglättete Partikel, hydrodynamische, Laserstrahlschweißen, Strahloptik, Strahlverfolgung, Wärmetransfer},
doi = {https://doi.org/10.1002/mawe.202300161},
year = {2024}
}






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