International Journal of Research in Engineering, Science and Management 358

Volume-1, Issue-9, September-2018

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Simulation of Heat Effected Zone in Welding

Process and Characterization of Arc, MIG and
TIG Welding Methods
A. Akshay Kumar1, D.V.Paleshwar2, Sainath Kasuba3
1
Student, Dept. of Mechanical Engineering, Sreyas Institute of Engineering & Technology, Hyderabad, India
2
Asst. Prof., Dept. of Mechanical Engineering, Sreyas Institute of Engineering & Technology, Hyderabad, India
3
Assoc. Prof., Dept. of Mechanical Engg., Sreyas Institute of Engineering & Technology, Hyderabad, India

Abstract—The application of the ferrous alloys plays the key Important aspects to note are as follows: (a) The temperature
role in the manufacturing industry. The process of joining starts at the ambient temperature of the environment prior to the
techniques and their effect on the metallurgical properties of the arrival of a moving heat source (b) the temperature rises very
metal greatly effects the strength of the joint and the life of the
product. In the current project the three different types of welding rapidly once the heat source acts on the point (c) the
techniques i.e. Tungsten Inert gas, Metal Inert gas and Arc temperature reaches a maximum or "peak" determined by the
welding are performed on AISI 1024 .The effect of these three balance between the energy being inputted and all losses (d) the
types of techniques on the series of steel alloys is tested by temperature remains at that maximum only as long as the source
destructive techniques. The microstructure, hardness and tensile remains on that spot (which, for a moving source, is only an
strength at the joints, HEZ and base plate are evaluated. instant) (e) the temperature cools back to the ambient level at a
rate dependent on the thermal mass and thermal-physical
Index Terms—AISI 4130, AISI 4140, AISI 4330, TIG, MIG,
ARC, Heat Effected Zone properties of the material and any imposed cooling.

I. INTRODUCTION II. LITERATURE SURVEY

The heat supplied by a welding arc produces complex A. Experimental Evaluation of Mechanical Properties
thermal cycle in the weldment and leads to creation of transient In the present analysis AISI 1024 5 mm thickness plates were
thermal stresses, and finally results in the creation of residual used for the analysis and the schematic model of weld
stresses in the weldment. The extent of this heating, in turn, preparation is given below.
affects the degree and nature of residual stresses in the newly
joined assembly. The temperature history of the welded
components also has a significant influence on the residual
stresses. The control of these temperature fields and cooling
rates is essential to ensure low residual stresses. The
measurement of surface temperatures during fission welding is
difficult, fairly complex and requires specialized equipment.
Therefore, recourse is to use quantitative calculations to gain
insight into the phenomenon of heat transfer during fusion Fig. 1. Welding sample preparation
welding. Theoretical analysis of the weld thermal cycle usually B. Specimen Preparation
requires number of simplifying assumptions regarding the
material properties of the melt and the high temperature
properties of the base metal. Arc efficiency is also an important
parameter to measure the efficiency of heat transfer during arc
welding processes. For all these reasons analysis of distribution Fig. 2. Tensile test specimen as per ASME SEC-IX: 2017
of heat and transient temperature cycle in fusion welds is
needed. In the weld pool, heat is transported by means of The test specimens of 5mm thickness were welded using
conduction and convection. Convective heat flow in welding Electric ARC, TIG and MIG with a single V groove as shown
cannot be accurately solved analytically because of its in the above figure. The filler material have melting point less
complexity; as a result the heat flow calculations made so far than that of the parent metal and are more elastic than the parent
are limited to simplified heat conduction calculations. metal therefore they prevent cracking in TIG welding with . The
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metals are welded with the filler metal used is ER70S for TIG B. Test Specimen for Tensile Test
welding, ER70S-3 electrode for MIG welding, E6010 electrode
for ARC welding.

1) Microstructure
The Microstructure of the base plate, weld bead are examined
for the evaluation of the other properties. The etchant is used as
NITAL 2% (HNO3 diluted with alcohol).
Fig. 3. Specimen of (a) Base plate (b) Arc Welding (c) TIG welding (d)
C. Mechanical Property Evaluation MIG Welding
1) Tensile test C. Tensile Test Graph of Base Metal
All the tensile properties for base plate were evaluated as per In the Fig. 4, the displacement i.e. strain on the specimen is
the standard IS 1608:2005 and for the all the weld specimens increased linearly with the load until 95 kN and then it attained
the test standards are carried as per the ASME standard ASME yield point and got fractured at 89.1 kN.
SEC-IX: 2017. The tensile test specimen configuration is
shown in Fig. 2 .The specimens were carefully machined using
a wire cut electrical discharge machine. The test was carried out
using a FIE 40 UTN-40 universal testing machine. The
properties like ultimate tensile strength, percentage of
elongation, proof stress and load were determined by using load
displacement data obtained during the test.

2) Microstructure
In order to identify the variation of properties in base metal,
weld regions on specimens, microstructure analysis was carried
out as per the ASTM standard E 407. For the welded specimen
the microstructure analysis were carried out at the fracture zone.

3) Hardness
The standard Vickers hardness test was conducted on both
weld regions as well as parent metal according to the standard
specified by IS 1501:2002.This test was carried out using
diamond indenter and load applied is equal to 10 kgs.
Fig. 4. Tensile test graph of base metal, ARC, TIG & MIG welded sample
III. RESULTS AND DISCUSSIONS
A. Tensile Test Results
D. Tensile Test Graph of TIG Welded Sample
The tensile strength was evaluated for all the weld specimens.
Initially the specimen undergone strain linearly and the
The Table-1, clearly shows that the base material is having
sample go fractured at 85 kN without any plasticity.
significantly high ultimate tensile strength as compared to that
of weld bead specimens. This value is 168% high as compared E. Tensile Test Graph of MIG Welded Sample
to arc weld specimen nearly 18% higher than GTAW specimen Initially the specimen undergone strain linearly and the
and nearly 82.3% higher than GTAW specimen. sample go fractured at 47 kN approximately without any
plasticity.

TABLE I
TENSILE TEST RESULTS OF ALL THE THREE TYPES OF WELDING SPECIMENS
Specimen Ultimate Ultimate tensile Elongation % Yield load Yield stress Original Final gauge
load strength gauge length
KN N/mm2 length
Base Material 96 906.088 16.98 85.82 809.981 58.17 68.05
Arc weld specimen 41.2 337.125 - - - - -
GTAW specimen 82.56 765.721 6.12 63.8 591.727 59 62.61
MIG 48.48 496.82 4.82 45.47 468.744 56 58.7
Specimen
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F. Microstructure TABLE II
MATERIAL PROPERTIES
Property Value
Density 8000 g/cc
Young’s modulus 190 GPa
Poisson’s ratio 0.29
Tensile strength 320 Mpa
Thermal conductivity 46 W/m-k

Fig. 5. Microstructure images of various joint zones (a) Base metal (b) Arc Fig. 6. Complete geometry of weld specimen, Weld bead geometry &
Welding (c) TIG welding (d) MIG Welding Symmetry model

J. Meshing
The microstructure consists of two eutectoid ferrite in the
matrix of ferrite. The matrix contains fine grains of ferrite. The model has been meshed with the required element size
The weld bead of arc welded specimen weld zone consists of and the mesh method.
columnar grains with grain boundary as ferrite and
windmanstatten ferrite in the matrix of pearlite.
The microstructure of TIG welded specimen consists of fine
grains of grain boundary ferrite with some windmanstatten
ferrite and polygon ferrite in the matrix of ferrite
Microstructure of MIG weld zone consists of coarse columnar
grains with grain boundary ferrite and windmanstatten ferrite in Fig. 7. Mesh model
the matrix of pearlite.
Boundary Conditions:
G. Hardness Test
The boundary conditions are calculated for the present model
Vickers hardness values are evaluated for all the three using some set of relations.
specimens (base metal, GTAW weld bead, FSW weld Boundary conditions needed:
bead).The result shows that GTAW weld bead hardness is  Heat source calculation.
marginally higher as compared to that of base metal and FSW  Convection parameters.
weld bead. The hardness values are presented in the Table. Heat source calculations:
𝑉𝑋𝐼
H. Study of Heat effected Zone by thermal Analysis Heat input =
𝑇
The present research work concentrates on the how the heat Where,
transfer is taking place when an arc welding torch is being V – Voltage = 21V
moved on the weld area of the plates. For the current analysis I – Amperes = 165A.
two plates of dimensions 200*150*5 mm AISI 1020 plates are 𝑉𝑋𝐼 165 𝑋 21
Heat input = = 1 = 0.54 kJ/mm
taken and simulated for the thermal distribution. 𝑇 0.38 𝑋
60
Arc travel time = 0.38 m/min
I. Material Properties 380
=
For the convenience of the simulation half symmetry model 60

is considered for the analysis. Standard weld bead geometry and = 6.3 mm/sec
gap between the two weld plates is maintained as per the ASME Wattage = Heat input * T mm/sec
welding standards. = 0.54 * 6.3
= 3.402 kJ/sec
TABLE III
ARC WELDING PARAMETERS
CTWD: 1/2” (13mm)
Plate Thickness(mm) 0.6 0.9 1.5 2 3 4 5 6
Electrode Dia (mm) 0.6 0.8 0.8 0.9 0.8 0.9 0.8 0.9 0.8 0.9 0.8 0.9 1.1 1.1 1.1
WFS – (M/min) 2.5 1.9 3.2 2.5 4.4 3.8 5.7 4.4 7 5.7 7.6 6.4 3.2 3.8 5
Amps (approximate) 35 35 55 80 80 120 100 130 115 160 130 175 145 165 200
Travel Speed (M/min) 0.25 0.25 0.35 0.33 0.33 0.5 0.45 0.45 0.5 0.5 0.43 0.5 0.45 0.3= 0.33
Voltage 17 17 18 18 19 19 20 20 21 21 22 22 18-20 19-21 20-22
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= 3.402 kW - L = 0.130, longer side of the fin, m

- β = air thermal expansion coefficient. For gases, is the reciprocal of the
temperature in Kelvin:
β = 0.033
- Tp = 75oC, Plate temperature, °C.
- Ta = 30oC, Air temperature, °C
= 3402 W - η = air kinematic viscosity, 1.6-5 at 30 °C.
𝑊𝑎𝑡𝑡𝑎𝑔𝑒
Internal generation per unit volume =
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑤𝑒𝑙𝑑 𝑏𝑒𝑎𝑑 9.81∗0.130∗0.130∗0.130∗0.033∗(75−30)
3402
Gr = 2
1.6−5
= Gr = 7.2*10-7
17.668
= 192.5 W/mm3
For plate temperature, Tp, set a expected value. Finally, the Prandtl number,
Transient Time Step: Pr is defined as:
The complete weld run is divided into 50 domains throughout
the weld run with a domain size of 3mm. Where:
The analysis is carried out for every 0.5sec and het input is - μ = air dynamic viscosity, is 1.865 at 30 °C.
- cp = air specific heat = 1005 J/(Kg*K) for dry air
given as per the time step. - k = air thermal conductivity = 0.026 W/(m*K) at 30 °C
Time travel = 0.38 m/min = 6.3 mm/sec 1.86−5 𝑋 1005
Pr =
Total time for welding 150mm is 23.08sec and it is rounded to 0.026
Pr = 0.7189
Convective heat transfer coefficient:
57.59 ∗ 0.026
ℎ𝑐 =
25 sec 0.130
ℎ𝑐 = 11.874 (For vertical walls)
For each bead the heat is made to generate for 0.5sec and rest ℎ𝑐 = 10.864 (For horizontal walls)
the heat is allowed to conduct to the plate.
Convection:
For convection we use the convection heat transfer coefficient
hc, W/(m2 K). A different approach is to define h through the
Nusselt number Nu, which is the ratio between the convective Fig. 8. Convection for vertical walls and horizontal walls
and the conductive heat transfer:
K. Simulation Results

Where:
- Nu = Nusselt number
- hc = convective heat transfer coefficient
- k = thermal conductivity, W/mK
- L = characteristic length, m
The convection heat transfer coefficient is then defined as Fig. 9. Temperature contour of the welding simulation at the end of
following: simulation
The Nusselt number depends on the geometrical shape of the heat
L. Graph
The below graph depicts the temperature distribution with
respect to the time, the temperature of 11000oC is achieved for
sink and on the air flow. For natural convection on flat the fraction of time at 25 sec, whereas a maximum temperature
isothermal plate the formula of Na is given in Table-4 of 8000oC is observed at every weldment of the specimen
TABLE IV
between 3 to 24 seconds.
NUSSELT NUMBER FORMULA

Where:

is the Rayleigh number defined in terms of Prandtl number (Pr) and Grashof
number (Gr). If Ra < 106 the heat flow is laminar, while if Ra > 106 the flow is
turbulent.
The Grash of number, Gr is defined as following:
Where: Fig. 10. Time vs. Temperature
- g = acceleration of gravity = 9.81, m/s2
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IV. CONCLUSION [5] L. Tall, "Residual Stresses in Welded Plates - A Theoretical Study,"
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