Three-Dimensional Thermal Finite Element Modeling for Keyhole Plasma Arc Welding of 2205 Duplex Stainless Steel Plates

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Author(s) M. A. Daha | G. A. Nassef | I. A. Abdallah | H. M. AbouSeeda
Pages 720-728
Volume 2
Issue 4
Date April, 2012
Keywords keyhole plasma arc welding, duplex stainless steel, finite element analysis, adaptive heat source model, weld geometry, temperature field


A three-dimensional thermal transient finite element model has been developed to estimate the weld geometry and to analyze the temperature field due to the keyhole plasma arc welding (PAW) in 2205 duplex stainless steel. An adaptive heat source model is proposed for the numerical analysis of the process, considering the “bugle-like” configuration feature of keyhole PAW welds. The thermal analysis has revealed temperature contours that indicate the size and geometry of the weld fusion zone (FZ). The initial models are validated against experimental data and show very good correlation. Such good correlation indicates the validity of the numerical heat transfer model and the analytical fluid flow model. A variety of welding heat inputs are then simulated. Effect of welding heat input on the size and geometry of the weld fusion zone are established.

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