Contents lists available at www.icmem.

tk

Manufacturing Engineering & Management The Proceedings

Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process
Aniruddha Ghosh
1 2 3

- Sergej Hloch2- Somnath Chattopadhyaya3

GovtCollegeofEngg&TextileTechnology, Berhampore, WB, India, Email: agmech74@gmail.com Faculty of Manufacturing Technologies, and TUKE with a seat in Preov, 080 01 Preov, Slovakia , Email: sergej.hloch@tuke.sk Dept of ME & MME,ISM,Dhanbad,India, Email: somuismu@gmail.com

ARTICLE INFO:
Category : Original Scientific Paper Received: 10 March 2012 / Revised: 30 October 2012 / Accepted: 11November 2012

Keywords: (in causal order)

Gaussian heat distribution Oval heat source shape Submerged Arc Welding

Abstract:
An attempt is made in this paper to find out the analytical solution of the thermal field induced in a semi infinite body by a moving heat source with Gaussian distribution by selecting appropriate inside volume for submerged arc welding process. It was revealed that for heat input of SAW process best suitable heat source shape was oval.

Citation: Ghosh A, et al. Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process , 2ndInternational Conference Manufacturing Engineering & Management 2012, (2012), p.6-14, ISBN 978-80-553-1216-3

INTRODUCTION
Several critical input variables e.g. current, voltage, electrode diameter, travel speed, wire feed rate, stick out and the like are involved in submerged arc welding. Temperature distribution during welding depends on these welding process parameters as heat input is function of these parameters[16].The shape of heat distribution changes with variation of input parameters of SAW process [13]. Study of temperature distribution of welded plates is very essential for designing submerged arc welding joint [14].An attempt of development of mathematical model of travelling heat source was made more than fifty years ago. After that, lots of research works have been continuing on this area. Initially two dimension surface Gaussian heat source with effective arc radius was adopted to find out temperature distribution on welded plates and weld pool geometry [10]. This solution was an improved version of estimation temperature distribution near heat source area in (x,y) plane but this solution is felt to find out temperature distribution along Z direction. However this attempt indicated new direction for finding out temperature distribution on welded plates. Then an analytical solution for transient temperature distribution for welded joint based on similar Gaussian heat distribution but different distribution parameters was introduced [19].These researches [10,19] are still limited to 2D heat source, so these solutions are felt to describe the effect of penetration. Recently this shortcoming has been overcome by considering 3D heat source. To estimate the temperature of the welded joints with deeper weld bead penetration, [15] first described 3D double ellipsoidal moving heat source and calculated three-dimensional temperature distribution through finite element modeling which could overcome the shortcoming of the two dimensional Gaussian model. Nguyen et.al.[25] presented an analytical solution of transient temperature distribution of a semi-infinite body subjected to three dimensional heat density of semi-ellipsoidal and double ellipsoidal mobile heat source. Very good agreement between predicted and measured temperature distribution data achieved assuming double ellipsoidal heat source. But there are still some limitations of this analytical solution, i.e. this solution is valid only for identical radii and heat dissipation of rear and front ellipsoid. Fachinotti, V. D.,et al. [11] proposed a semi-analytical solution which was able to overcome the aforesaid limitations. Nguyen et al. [26] again described an approximate analytical solution for double ellipsoidal heat source in finite thick plates. Their approximate solution can be directly used for simulation of welding of finite thick plate without the need for applying the mirror method as required in a semi-infinite body. It is an effective tool for finding thermal stress and microstructure modeling. Many problems of welding encountered in practice involve complicated geometries with complex boundary conditions or variable properties, and cannot be solved analytically. In such cases, sufficiently accurate approximate solutions can be obtained by computers using numerical methods. Ravichandran et al. [31] developed a model of temperature distribution during circumferential arc welding of spherical and cylindrical components using the finite element method and got very good results. Employing many simplifying assumptions in the mathematical model, Chandra [9] described the extension of Rosenthals method for the estimation of thermal field in a pipe with a mobile heat source. Many researchers gave importance on experimentations for finding out temperature distribution of welded plates. Akkus (2009) investigated the effect of sheet thickness, current density on speed of cooling and distribution of temperature in resistance spot welding by experiment. In this work, it is found thicker sheets have higher temperatures in weld zone. Heat generation in welding zone was affected by current density and sheet thickness. Veenstra et al. [34] measured temperature between electrodes for RSW by applying thermal method and Bentley et al. [4] investigated temperature distribution in RSW by applying metallographic method. Kermanpur et al. [20] investigated experimentally temperature distribution of GTAW process for butt weld. Maheshwari et al. [23] used thermocouples to measure temperature at different locations of GMA welded plates. Temperature readings are taken in every 10 seconds interval and temperature profile are generated for GMAW process which may be helpful to optimize the GMAW. In spite of more laborious and time temperature distribution obtained by experiment has some

Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process

A.Ghosh et al.

advantages.Researchers [11,25,26] investigated analytical solution of thermal field based on heat conduction, without considering heat lost through convection and radiation. But practically the three modes of heat transfer occur in welding process. Gutierrez and Araya [17] conducted the numerical simulation of the temperature distribution generated by mobile heat source by the approach of control volume. Here convection and radiation effect have been considered. Bianaco et al. [5,6] numerically solved the two and three dimensional models for evaluating transient conductive fields due to moving heat source. Bianco et.al. [6] investigated transient threedimensional temperature distribution numerically by COMSOL Multiphysics 3.2. Radiation and convection modes of heat transfer from work piece surfaces as well as variable thermophysical properties are taken into account. They found that surface heat transfer strongly affected the temperature distributions in the workpiece. Assuming constant thermal properties of material, Ohring and Lugt, [27] considered radiative heat transfer, evaporation, and viscous stress to find out temperature distribution. Mundra et al. [24] considered specific heat and thermal conductivity values for solid and liquid metal only. From the above, it is clear that heat transfer mechanism in a molten pool is extremely complex and its physics is not well understood, Biswas, and Mandal , [8] analyzed a numerical model with the aid of the finite element package ANSYS for single pass single sides submerged arc welding of square butt joints and the distortion of welded joint was determined. In their study, heat lost through natural heat convection is considered. Sabapathy et.al.[32,33]and Klobcar et.al[21]attempted to find out thermal field on welded plates for MMA welding process considering flatter and more evenly distributed heat than Gaussian and found excellent comparison with measured data.Ghosh et.al.[12,13] investigated heat source shape for submerged arc welding procees.But their investigation, till near about 10% error in prediction of transient temperature distribution was found. In this analysis, an attempt is made in this paper to find out the analytical solution of the thermal field induced in a semi infinite body by a moving heat source with Gaussian heat distribution by selecting inside volume of oval shape for submerged arc welding process.

by infrared thermometers (OMEGA SCOPE OS524E, temperature range 2482, accuracy is 1% rdg or 2 which ever is greater, resolution 1 ,response time 10ms).

Fig. 1 Representation of axes and identification of few points (P1, P2, P3, P4) where reading of temperature was taken The job is cut at three sections of welded plates when flux has been used. The samples are prepared by standard metallographic process and the average values of the penetration, reinforcement height are measured using digital venire caliper of least count 0.002 cm. Table-1 depict the weld parameters of SAW considered in present work. The measured values of weld dimensions and corresponding welding conditions are described in Tab. 2. Tab. 2 Observed values for bead parameters
Reinforcement Height(mm) 2.38 2.34 3.16 2.76 1.00 1.78 2.25 1.94 Travel Speed (cm/min) Penetration (mm) Bead Width (mm) 17.96 21.90 21.00 30.92 13.94 20.12 15.90 22.66

Voltage (V) 25 35 25 35 25 35 25 35

1 2 3 4 5 6 7 8

A1 A2 A3 A4 B1 B2 B3 B4

Current (A) 350 350 450 450 350 350 450 450

Job No.

Sl.No.

17 17 17 17 30 30 30 30

6.70 3.72 6.69 8.26 5.28 4.58 6.60 7.78

EXPERIMENTAL METHOD
MEMCO semi automatic welding machine with constant voltage,retifyer type power source with a 1200-A capacity was used to join C-Mn steel plates 30152cm.ESAB SA1(E8),0.315cm diameter,coper coated electrode in coil from and ESAB brand ,basic fluoride type granular flux used. The experiments were conducted as per the design matrix randomly to avoid errors due to noise factors. Two pieces of C-Mn steel plates were cut and V groove of angle 60o as per the standards were prepared. The chemical composition of work piece material is described in Table 1. 0.1 cm root opening was selected to join the plates in the flat position keeping electrode positive and perpendicular to the plate. The job was firmly fixed to a base plate and then the submerged arc welding was finally carried out. Tab. 1 Chemical composition of C-Mn steel work piece (in %)
C Sn Mn P S Cr Ni Mo Cu Al 0.18 0.36 1.58 0.023 0.027 0.06 0.03 0.01 0.04 0.05

The welding parameters were recorded during actual welding to determine their fluctuations, if any. The slag was removed and the job was allowed to cool down.Temperatures are recorded at different points of the welded plates (as shown in fig.1) except welding line

Material Properties: In the present analysis, C-Mn mils steel has been used. Table-3 shows the temperaturedependent material properties (Mahapatra et. al. (2006)) used for the transient heat transfer and HAZ analysis.Thermal Modeling: A three dimensional thermal model through approximate analytical solution is developed in the present work to analyze the heat transfer and temperature distribution in submerged arc welding. In the literature, models for both conduction and convection are available. From the literature survey it is clear that the heat transfer mechanism in a molten pool is extremely complex and its physics is not well understood. Although some progress has recently been made towards a proper modeling of convective heat transfer, these efforts are still directed towards a proper modeling of convective heat transfer, these efforts are still directed towards simple cases. The various material properties of metals in the molten state are also not authentically established. In arc welding, except for a small volume of metal, most portions of work specimen remain in the solid state. Therefore a three dimensional thermal model was considered to analysis the heat transfer and the resulting temperature distribution.

Ghosh A. et al.

Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process

Tab. 3 Variation of thermo mechanical properties with respect to temperature of C-Mn Steel (Mahapatra et. al. (2006):
Thermal expansion coefficient(10 -6 / Young modulus(GPa ) Temperature () Poisson ratio Thermal conductivity (W/mK) Specific heat(J/kgK)

combination of two semi ellipsoidal (one has major axis af and other ar). For this study, combination of semi ellipsoids is assumed to be an oval shape. These combination of two semi ellipsoidal shapes was called double ellipsoidal heat source configuration. In present study it was found for experiments that shape of weld pool geometry was oval.For job B4 of table-2,equation of oval weld pool geometry was (as shown in fig.3). So ,heat source shape for this study was assumed as an oval shape(as shown in fig.3) whose equation is

0 100 300 450 550 600 720 800 1450 1510 1580 5000

52 51 46 41 37.5 36 31 26 29.5 29.7 29.7 42

450 500 565 630.5 705.5 773.3 1080 931 438 400 735 400

10 11 12 13 14 14 14 14 15 15 15 15.5

200 200 200 150 110 88 20 20 2 0.2 0.00002 0.00002

0.28 0.31 0.33 0.34 0.36 0.37 0.37 0.42 0.47 0.5 0.5 0.5

Assumption made in thermal model: In developing the thermal model, an attempt has been made to accommodate the actual welding conditions as far as possible. However, the following have been assumed in the thermal model of the welding process. Density was remains constant and did not change with temperature change. All other thermal properties ware considered as a function of temperature. Convective heat lost through all surfaces of welded plated. Heat loss due to radiation. Heat Source Model: The heat source model, defining the distribution of the heat input due to the welding arc, has an important effect on the heat distribution pattern in the vicinity of the weld zone. It is in this region where the fusion zone and the heat affected zone are formed. It is therefore important to study the effect of heat input distribution on the size and shape of these zones. For analyzing the heat flow pattern on welded plates, the heat input can be treated as distributed heat source. In the literature, many heat source distributions through Gaussian manner of inside volume ellipsoidal, double ellipsoidal, double central conicoidal, bell (2D), was described(Ghosh et. al.(2011). In present work ,oval heat source considered and found most suitable heat source shape.It was found from literature (Nguyen et.al.(1999),Ghosh et. al.(2011)that most suitable heat source is combination of two semi ellipsoidal shapes. Semi major axis of one of these ellipsoids was af another was ar as shown in fig.2.

Fig.3 Comparison of ellipse (

) and oval

shapes.It was found from experiment that shape of weld pool geometry is oval and equation of weld pool geometry for B4 job (of table-2) is , wherem=0.3forthisstudy (1) Where af+ar=a= semi major axis, b=semi minor axis, c=another semi-principal axis of an ellipsoid whose equation is .It can be realized from fig.3. Let us consider a fixed Cartesian reference frame x, y, z as shown in fig. 1. Initially proposed a oval heat source (as shown in Fig.2,3) in which heat is distributed in a Gaussian manner throughout the heat sources volume. The heat density q(x, y, z) at a point(x, y, z) with in oval shape is given by the following equation:
( q(x, y, z) = A ( (1) [Where A is Gaussian heat distribution parameter and a, b, c, m are oval heat source parameters] If Q0 is the total heat input, then

2Q0 = or A=

( Q0 (2)

Oval shape heat distribution equation is: q(x, y, z) =

Q0

(3)

Fig.2 Double ellipsoidal heat Source described by Henwood et al.(1988).Double Ellipsoidal Heat Source Configuration i.e. it is a

Here,Q0=IV; (4) V,I,=welding voltage, current and arc efficiency respectively. Arc efficiency is taken 0.9 for submerged arc welding process. Analytical solution: Transient temperature field of oval shape heat source in a semi-infinite body is based on

Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process

A.Ghosh et al.

solution for the instant point source that satisfied the following differential equation of heat conduction of fixed coordinates (Nguyen et al., 1999).Moving Double Oval Heat Source Problem:Let us consider a heat source located at x = 0 at time t = 0 moves with constant velocity v along the x axis and heat emitted at a point(x, y, z) at an instant t by the oval heat source. Mathematical expression of oval heat source is q(x, y, z) =

due to the point heat source dQ at time t ;( x, y, z) = location of instant point heat source dQ at time t. Here: Iz=
( ( ( ( ( (
( ( ( (

dz
)

(13)

( (
( (

Q0

(5)

I y =

dy

(14)

Induced Temperature Field: Heat conduction in a homogeneous solid is governed by the linear partial differential equation k T + q =
2

Ix = =[ x [
( (

(
(

)
(

dx
( ( ) ) ( ( ) )

(6)

Where T = T(x, y, z, t) is the temperature at point(x, y, z) at time t, q is the heat source, is the density, c is the heat capacity and k is the thermal conductivity of the plates of welded plates.The fundamental solution of equation (6) is the Green function,i.e. G (x-x, y-y,z-z,t-t) = =
( (
( ( ( ) (

(x) +
( ) ( ( ) (
( ( ) ) ( ( ) )

] (x)

(15)

(7)

Where = k/(c) is the thermal diffusivity. Equation (7) gives the temperature increment at point(x, y, z) and at instant t due to an instantaneous unit heat source applied at point (x, y, z) at instant t, assuming the body to be infinite with an initial homogeneous temperature. Then, due to the linearity of equation (7), the temperature variation induced at point(x, y, z) at time t by instantaneous heat source of magnitude q (x, y, z, t) applied at (x, y, z) at time t is q (x, y, z, t) G (x-x, y-y, z-z, t-t) (8) Assuming that heat has been continuously generated at point (x, y, z) from t=0, the temperature increment at point(x, y, z) at time t is ( G (x-x, y-y, z-z, t-t) dt (9) If we assume that the heat has been continuously generated from t=0 throughout an infinite medium, the temperature increment at any point (x, y, z) and at any instant t takes the form T(x, y, z, t) = z, t-t) dt ( G (x-x, y-y, z(10)

Ix has been calculated by applying numerical method taking appropriate values of integration upper and lower limit. When heat source is moving with constant speed v from time t=0 to t=t, the increase of temperature during this time is equivalent to the sum of all the contributions of the moving heat source during the travelling time as: T(x, y, z, t) T0= dt (Where =f (x-vt),when Ix =f(x))
(

(16)

Calculation of Oval Shape Bead Geometry parameters: Let the A, B, C are the Oval Shape Bead Geometry parameters. It has been literature (Goldak and Akhlaghi, 2005), q (A, 0,0) =q(0) =0.05 q (0) a=
( (

(17) (18) (19)

Similarly, b= c=
(

Then the temperature induced by the oval heat source defined by equation is T(x, y, z, t) = dt
(

(11)

Finally, by assuming the body was initially at the homogeneous temperature T0, the temperature field is defined by T(x, y, z, t) T0= dt
(

Values A, B, C can be measured from weld bead geometry,B=half of the bead width,C=Penetration and A = half of the major axis of oval shape=1.15B( experimentally found i.e. through weld pool measurement for submerged arc welding process). Experimentally measured values A, B, C are applied to find out the values temperature distribution of equation No-16.Actually thermal diffusivity, thermal conductivity, specific heats of material are changed with change of temperature. So to get better results again approximate solution of transient temperature distribution has been developed considering variation of thermomechanical properties w.r.t. temperature, which is described below.From equation No.1 to 10, it can be written that dT= dt Or dT= dt(as )
( (

(12)

Where =thermal diffusivity, c_p=specific heat, =mass density; t, t =time; dTt=transient temperature change

(20)

Ghosh A. et al.

Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process

a Or From data of thermo mechanical properties of table 3 and with the help of MATLAB, relations between thermo mechanical properties and temperature have been developed which are described in table 7.Putting the mathematical expression in equation 20,we get ( (
=
(

b ( ( (21) ) ) (

Or ( (

Calculation of a,b,c have been done with the help of equations 17,18,19.Solution of this equation (equation 21)has been completed with the help of Horners method. Value of m is equal to 0.2 has been assumed for this study. 5.4Consideration of convection Heat input (Q0) =Conductive heat flow ( ( (neglecting radiation) Let a block of dimension dx, dy, dz, convective heat transfer coefficient h, So it can be written that Heat input (Q0) = ( ( ( So, = (1= (1= (1Q0=0.9 (from table -8) ) = (1(as,dz=plate thickness=L)

Comparison of measured and estimated temperature distribution through analytical solution with the help of past history considering different types of heat source on (25, 15, 0). Here x axis denotes time and Y axis denotes (T-T0),where T0 is initial temperature of base metals. c

Comparison of measured and estimated temperature distribution through analytical solution with the help of past history considering different types of heat source on (25, 20, 0). Here x axis denotes time and Y axis denotes(T-T0),where T0 is initial temperature of base metals. d

So, equation can be written in this way when convective lost is assumed
( ( ) ( ( =

Calculation of a, b, c have been done with the help of equations 17,18,19.Solution of this equation(equation 22)has been completed with the help of Horners method.

RESULTS AND DISCUSION

With the help of equation 22 and literature survey (Ghosh et. al.(2011)), transient temperature was calculated and compared with measured data which are shown in fig.4.It was found that most suitable heat source shape is oval.

Comparison of measured and estimated temperature distribution through analytical solution with the help of past history considering different types of heat source on (0, 0, 2 0). Here x axis denotes time and Y axis denotes (T-T0), where T0 is initial temperature of base metals. Fig.4 Comparison of measured and estimated temperature distribution through analytical solution with the help of past history considering different types of heat source. Prediction of Penetration Weld bead penetration of a structural steel is the region heated from atmospheric temperature (i.e., 273) to the melting point temperature of welded materials (i.e.1464). Putting these values in the equation (22),

10

Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process

A.Ghosh et al.

penetration(s) can be calculated at y=0, x=vt, t=t=travel time of electrode, which are tabulated in table 4. Tab.4 Comparison of predicted and experimental values of penetration Penetration Penetration % error (mm) (mm) (Experimental Values) (Predicted Values) 6.70 7.36 10 3.72 4.1 9 6.69 7.34 9.5 8.26 9.08 10 5.28 5.78 9.8 4.58 5.03 9.9 6.60 7.26 9.8 7.78 8.55 9.9 PREDICTION OF WELD BEAD WIDTH Weld bead width of a structural steel is the region heated from atmospheric temperature (i.e., 723) to the temperature the melting point temperature of welded materials (i.e.1464). Putting these values in the equation (22), half of weld bead(s) can be calculated at z=0, x=vt, t=t= travel time of electrode, after that multiplying by two bead width(s), the results are tabulated in table 5. Tab.5 Comparison of predicted and experimental values of weld bead width Weld Bead Width Weld Bead Width % error (mm) (mm) (Experimental Values) (Predicted Values) 17.96 19.73 9.9 21.90 23.91 9.2 21.00 23.00 9.6 30.92 34.01 10 13.94 15.29 9.7 20.12 22.09 9.8 15.90 17.47 9.9 22.66 24.90 9.9 PREDICTION OF HAZ WIDTH HAZ width of a C-Mn steel is the region heated from lower critical temperature (i.e., 723 ) to the temperature just below the melting point temperature of welded materials (i.e. 1464). Putting these values in the equation (22) HAZ width(s) can be calculated at z=0, x=vt, t=t= travel time of electrode which are described in table-6. Tab.6 Predicted HAZ width(s) Measured HAZ width(mm) with the help of hardness variation Calculated HAZ width(mm) the help of equation -22 Calculated HAZ width(mm) the help of equation -23

Tab.7 Mathematical relation of thermo mechanical properties and temperature Relation with temperature thermo mechanical property

1 2

K (

( )

Tab.8 Calculated values of (1-

) with the help of (1) 0.90 0.90 0.90 0.90 0.90 0.90 0.90 0.90 0.90 0.90

data,described in table-3 Temperature Thermal (Thermal 2 1/2 ( ) diffusivity(m /sec) diffusivity) 0 100 300 450 550 600 720 800 1450 1510 0.000015 0.000013 0.000010 0.000008 0.000007 0.000006 0.000004 0.000004 0.000009 0.000009 0.004 0.004 0.003 0.003 0.003 0.002 0.002 0.002 0.003 0.003

Prediction of HAZ widthin alternative way Let, equation of an oval Shape Bead Geometry Ax2+ (By2+Cz2) f(x) =1, where A, B, C are the oval shape bead geometry parameters. It has been found from literature [Goldak (2005)] that, q (A, 0, 0) =q (0) ( a=
(

. Similarly, b=

, c=

Value of B(mm)

Let equation of oval Shape heat affected zone boundary (curve-2) Ax2+ (By2+Cz2) f(x) =1, where A, B, C are the oval Shape heat affected zone boundary parameters. Heat density at the boundary of oval Shape Bead Geometry=cp(Tmelt T0), where density of welded material, cp is the specific heat of this material, Tm melting point temperature of welded material, T0 is the atmospheric temperature. Heat density at the boundary of heat affected zone =cp(ThazT0), where Thaz is the lower critical temperature(i.e.723) temperature of welded material. So, Or, =
( (
( (

Sl No.

( (
( (

( (

( (

1 2 3 4 5 6 7 8

1.1 1.3 1.3 1.9 0.9 1.2 1.0 1.4

1.2 1.5 1.4 2.1 0.9 1.4 1.1 1.5

1.2 1.4 1.4 2.0 0.9 1.3 1.1 1.5

1.12 1.33 1.32 1.92 0.91 1.22 1.01 1.56

( ( ( (

)( ( ) )( ( )

Or,

( (

11

Regression coefficient R2(%) 96 99

Mathematical Model

Sl.No

Ghosh A. et al.

Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process

As, Tmelt =14640C,Thaz = 7230C, ( 0.05q (0) 0 and assuming atmospheric temperature is equal to 30 C. So it can be written, =1.1224 So, (B B) =0.1224B Or, HAZ width=0.1224B (23) With the help of table-2 and eqation-23, HAZ width(s) have been calculated which are also described in table-6. VALIDATION OF PREDICTED DATA OF HAZ WIDTH To validate predicted HAZ width, measurement of hardness on welded zone and non welded zone (as shown in fig.5) and analysis of microstructure (as shown in fig.6) were carried out. a

the hardness values are low and prominent grain growth (as shown in fig-6c) was found at just below the fusion zone. a

Microstructure at the non welded zone (as shown in fig.5c) of 3000 magnifications for 2.84 kJ/mm heat input. Negligible grain growth portion. b

Hardness values are recorded at different grid junctions of the welded specimen (distance between two grid points is equal to 2 mm) b

Fringe plot of hard variation of submerged arc welded plates.Here, HAZ width is equal to 0.156 cm or 1.56mm (for the job-A4, heat input for the process is 2.84KJ/mm). c

Microstructure at the welded zone (as shown in fig.5c) of 3000 magnification for 2.84 kJ/mm heat input. Few points are prominent grain growth in this microstructure; these are the softening portion of welded zone C

Identification of different portion of submerged arc welded plates Fig.5 Hardness Variation of welded plates Negligible grain growth portion was found form the analysis of microstructure at the non welded zone(as shown in fig6a) . But, in few points, prominent grain growth ware found9as shown in fig6b). These are the softening portion of welded zone. Microstructure at the Heat Affected Zone. Here more softening portions were found w.r.t welded portion (as shown in fig.6c) because temperature of this portion exceeded from recrystalisation temperature of the metal for a time. That is why prominent grain growth ware found. This is the Heat Affected Zone. It was found by measuring hardness (as shown in fig.5b,c) that at just below the fusion zone,

Microstructure at the Heat Affected Zone (as shown in fig.5c) of 3000 magnification for 2.84 kJ/mm heat input. Here more softening portion w.r.t welded portion. This is the Heat Affected Zone. Fig.6 Microstructure Variation of welded plates Around 1.56 mm in both side at just below the fusion zone the hardness values (as shown in fig.5b) are comparatively low. This low hardness and prominent grain growth portion is the heat affected zone (HAZ). Above description

12

Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process

A.Ghosh et al.

proves that HAZ width 1.56 mm for 2.84 kJ/mm heat input in welding process which compares well with the above predicted HAZ width data as given in Table 6.

CONCLUSION
1.Heat distribution on welded plate is Oval shape for Submerged Arc Welding process and heat source parameters of this heat source can be measured from the dimension of bead geometry. 2.Transient temperature distribution on welded plate can be calculated with the help of Gaussian Oval shape Heat distribution technique. 3.In this study, analytical solutions for the transient temperature field of a semi infinite body subjected to 3D power density moving heat source (such as oval shape heat source, which is first time attempted in this work) were found and experimentally validated. The analytical solution for oval shape heat source was used to calculate transient temperatures at selected points on a mild steel plates which are welded by taking x- axis along welding line, origin is starting point of welding, yaxis is perpendicular to welding line and z-axis towards plate thickness. Both numerical and experimental results from this study have showed that the present analytical solution could offer a very good prediction for transient temperatures near the weld pool, as well as simulate the complicated welding path. Furthermore, very good agreement between the calculated and measured temperature data indeed shows the creditability of the newly found solution and potential application for various simulation purposes, such as thermal stress, residual stress calculations and microstructure modeling. 4.Bead geometry dimensions have been calculated with the help of analytical solution (described in this paper). Very good agreement between the calculated and experimental values. 5.Prediction of HAZ width has been made with the help of three dimension transient temperature distribution equation. It is also new technique which is not previously applied. 6.Existence of prominent grain growth provides the confirmatory evidence of the HAZ softening phenomenon. In the welded portion, grain refinement occurs in most of the region due to the heating and cooling cycle of SAW method. Predominant direction of the grain growth is clearly observed from the photograph of the microstructure. This grain formation is distinctly revealed in the magnification (50,100) for the heat input of 2.84 kJ/mm. Hall Petch equation states the strength of the metal is to vary reciprocally with size of subgrain.The similar phenomenon is also revealed in case of hardness. In the context of this equation one can say that the hardness of the grain growth portion will also manifest lower values related to higher grain sizes. In the grain growth portion of the welded region longer grains have been found depicting the chances of dislocation, slip, low yield strength and low hardness values measured in Rockwell scale B. 7.Validations of calculated HAZ width through analysis of microstructure changes(comp. Fig.6) and hardness analysis have been made. Very good agreement has also been found for this case.

REFERENCES
[1] Akkus, A. (2009) Temperature distribution study in resistance spot welding. Journal of Scientific & Industrial Research, 68, 199-202.

[2] Ali, Y., M., Zhang, L., C. (2005). Relativistic Heat Conduction. International Journal of Heat Mass Transfer, 48 2397-2406. [3] Ali, Y., M., Zhang, L., C. (2005) Relativistic Heat Source, International Journal of Heat Mass Transfer, 48, 2741-2758. [4] Bentley, K, P., Greenwod, J., A., P.Knowlson, P., Baker, R., G. (1963). Temperature distribution in spot welds, Brit Weld J., 10, 613-619. [5] Bianco, N., Manca, O., Naso, V. (2004). Numerical analysis of Transient Temperature Fields in Solids by a Moving Heat Source, HEFAT2004,3rd Int.Conf. on Heat Transfer, Fluid Mechanics and Thermodynamics, paper n BN2, 21-24. [6] Bianco, N., Manca, O., Nardini, S.(2008), Two Dimensional Transient Analysis of Temperature Distribution in a Solid Irradiated by a Gaussian Lesser Source, Proc. ESDA2004-58286 7th Biennial Conf. on Engineering Systems Design and Analysis July 19-22. [7] Bianco, N., Manca, O., Nardini, S. ,(2006). Transient Heat Conduction in Solids Irradiated by a Moving Heat Source. Excerpt from the Proceedings of COMSOL User Conference 2006 Milano. [8] Biswas, P., Mandal, N., R. (2009). Thermomechanical Finite Element Analysis and Experimental Investigation of Single Pass Single Sided Submerged Arc Welding of C-Mn Steel Plates,Proc. IMechE Vol.224 Part B: J.Engineering Manufacture, 627 639. [9] Chandra, U. (1985). Determination of residual stresses due to girth butt welds in pipes. Trans. ASME J. Press. Ves. Technol, 107, 178-184. [10] Eager, T., W., Tsai, N., S. (1983). Temperature fields produced by traveling distributed heat sources. Welding Journal, 62(12), 346-355. [11] Fachinotti, V. D., Cardona, A. (2008) Semi-analytical Solution of the Thermal Field Induced by a Moving Double-Ellipsoidal Welding Heat Source in a SemiInfinite Body. Asociacion Argentina de Mecanica Computacional 10-13, 1519-1530. [12] Ghosh, A.,et.al., (2011),Prediction of Temperature Distribution on Submerged Arc Welded Plates through Gaussian Heat Distribution Technique, Advanced Materials Research, Volumes 284 286,,pp. 2477-2480. [13] Ghosh,A.,et.al., (2011),Prediction of Weld Bead Penetration, Transient Temperature Distribution& HAZ width of Submerged Arc Welded Structural Steel Plates, Defect and Diffusion Forum Vols. 316-317,pp 135-152. [14] Goldak, J., A., Akhlaghi, M., (2005). Computational Welding Mechanics. Springer.71-115. [15] Goldak, J., Chakravarti, A., Bibby, M., A Double Ellipsoidal Finite Element Model for Welding Heat Source, IIW Doc.No212-603-85. [16] Gunarajan, V., Murugan, N., 2002. Prediction of Heat Affected Zone Charecteristics in Submerged Arc welding of Structural Steel Pipes. Welding Research, 94-98. [17] Gutierrez, G. Araya, J., G., (2003). Temperature Distribution in a finite Solid due to a Moving laser Beam. Proc. IMECE2003-43545,2003 ASME Int. Mech.Eng.Congr.,Washington,D.C.November, 15-21.

13

Ghosh A. et al.

Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process

[18] Javadi, Y. (2010) Influence of Fixture on Welding Distortion, Proc. Int. Conf. on Advanced Topics in manufacturing Engineering and Management. University of Czestochowa, Faculty of Management, Czestochowa, 9-13. [19] Jeong, S., K., Cho, H., S., (1997) An analytical solution to predict the transient temperature distribution in fillet arc welds. Welding Journal, 76 (6), 223-232. [20] Kermanpur, A., Shamanian, M., Esfahani, V., Yeganesh, V. (2009). Three dimensional thermal simulation and experimental investigation of GTAW circumferentially butt welded Incoloy 800 pipes. Journal of Material Processing Technology 199, 11021. [21] Klobar, D. , Tuek,J., Taljat, B., Finite element modelling of GTA weld surfacing applied to hot-work tooling, Computational Materials Science 31 (2004) 368378. [22] Mahapatra, M.M., Datta, G.L., Pradhan, B., 2006,Mandal, N.R., Three-dimensional finite element analysis to predict the effects of SAW process parameters on temperature distribution and angular distortions in single-pass butt joints with top and bottom reinforcements, International Journal of Pressure Vessels and Piping 83,pp. 721729. [23] Maheshwari, A., Harish Kumar Arya,(2010) Surendra Kumar and Coolant Singh: Experimental Determination of weld pool temperature and to generate temperature profile for GMAW,Proc. 2nd International Conference on Production and industrial enginneering, NIT, jalandhar,India,paper 45. [24] Mundra, K., et. al. (1997). Weld Metal Microstructure Calculation from Fundamentals of Transport Phenomena in the Arc Welding of Low Alloy Steels. Weld. J., 163-171. [25] Nguyen, N., T., et al., (1999). Analytical Solution for Transient Temperature of Semi-Infinite Body

Subjected to 3-D Moving Heat Sources. Welding Research, August 265-274. [26] Nguyen, N., T., Mai, Y., W., Simpson, S. Ohta, A. (2004). Analytical Approximate Solution for Double Ellipsoidal Heat Source in Finite Thick Plate. Welding Research, 82-93. [27] Ohring, S., Lugt, H., J. (1999), Numerical Simulation of a time dependent 3D GMA weld pool due to a Moving Arc. Weld. J., 79(120), 416-171. [28] Ogwuagwu, O., V., (2006), Simulation of Heat Transfer in Thin Plates during Arc Welding, AU J.T.10 (1): July 2006, 52-54. [29] Pillai, K.,R., et al., 2007. Some Investigations on the Interactions of the Process Parameters of Submerged Arc Welding. Manufacturing Technology & Research, 3, 57-67. [30] Postacioglu, N., Kapadia, P. Dowden, J., M. (1997). The Thermal Stress generated by a Moving Elliptical Weld pool in the Welding of thin Metal Sheets. J.Appl.Phys, 30, 2304 -2312. [31] Ravichandran, G., Raghupathy, V., P., Ganesan, N. (1996) Analysis of Temperature Distribution during Circumferential Welding of Cylindrical and Spherical Components using the Finite Element Method. Computer and Structures, 59, 225-255. [32] Sabapathy, P.N., Wahab, M.A. , M.J. Painter, The prediction of burn-trough during in service welding of gas pipelines, International Journal of Pressure Vessels and Piping 77 (2000) 669677. [33] Sabapathy, P.N. , Wahab, M.A. , Painter, M.J.,Numerical models of in-service welding of gas pipelines, Journal of Materials Processing Technology 118 (2001) 1421. [34] Veenstra, P., C., Hults, A. (1969) A Thermal Model of Spot Welding Process (Greve Offset NV, Eindhoven)

14