3.

HEAT FLOW CHARACTER IN WELDING

3.1 INTRODUCTION
Scope of this report is to discuss heat flow character in welding and the different timetemperature relations in detail.

3.2 THE EQUATION OF HEAT FLOW

The familiar Fouriers heat flow equation is the starting point for the discussion of heat flow in a fusion weld. It has been modified and presented below d2/dx2 d2/d!2 d2/d"2 #2d/dt

$here #temperature o%er ambient& is half of the thermal diffusi%it!. This equation has been deri%ed for a stationar! heat source. In fusion welding &heat source& whether it is an arc or a gas torch is in motion. Therefore equation must be modified b! introducing a parameter defined b! #x-%t where is a rectangular coordinate in the direction of tra%el of the point source& % is the %elocit! and t is the time. Figure ' shows the relation

fig '

The equation in &! and " co-ordinates is

The form of equation ( suggests that a solution ma! be found of the form

In this equation ) is proportional to amount of heat input. This is related to the watts of the arc& is a function of &! and " and must be determined. This function must satisf! an equation that is the result of substituting * into (.

+quation , must be sol%ed to find the function in terms of &! and ". The actual solution would depend on the boundar! conditions.

3.2.1 B OUNDARY C ONDITION

) solution has been obtained for equation , for the following boundar! condition '.It is assumed that there is no heat transfer across the surface of plate. This requirement ma! be expressed mathematics as d/d"#- where "#-&h where h is the thic.ness of the plate. This boundar! condition is not exactl! fulfilled since there is some heat loss through the bottom of the plate. 2.It is necessar! to use the fact that at %er! large distance from the heat source there is no heating up. This means that TT- or - as / where /#02 !2 "21'/2 (.$e assume that all the heat enters the plate at a true mo%ing point. This we .now is not so because a flame ob%iousl! has width. The cathode point of an arc is %er! nearl! a true point source& but it tends to wander as the weld progresses. )s the distance from the centre line increases the error rapidl! becomes negligible.

3.2.2 T HIN , T HICK AND S EMI - INFINITE PLATES

The plate thic.ness ma! be regarded as a .ind of boundar! condition and secondl! the complexit! of the answer depends upon plate thic.ness. )ll the plates are considered to be infinitel! wide. The three classes of plate thic.ness are readil! %isuali"ed in terms of the temperature pattern on the bac. of the plate while the arc is passing o%erhead. Thus if the plate is thin the bottom of the plate will be 2ust as hot as the top of the plate.

) plate that is thic. enough so that isotherms across a cross-section show a bend. Such a thic. plate is shown in figure (.the isotherms are crowded slightl! closer than the! were in the thin plate. This is a result of the fact that more mass is beneath the heat source to absorb the heat. The bottom of the thic. plate heats up but not as much as the top and the pea. temperature on the bottom is reached after the arc passes b!.

Finall! a plate so thic. that the bottom ne%er heats up to an! appreciable extent is called a semi-infinite plate. For steels such a plate is thic.er that about *inch.)luminium must be somewhat thic.er to be considered a semi-infinite plate.

3.2.3 T HE E QUATION FOR T EMPERATURE D ISTRIBUTION IN THE T HICK P LATE

The temperature distribution in a thic. plate that is infinitel! wide is gi%en b!

3.2.3 T HE E QUATION FOR T EMPERATURE D ISTRIBUTION IN THE T HICK P LATE

The temperature distribution in a thic. plate that is infinitel! wide is gi%en b!

The complexit! of this equation ma.es the actual calculation of the temperature distribution in a plate during welding quite tedious. The terms within the summation are referred to as reflection terms. The entire series summation could be omitted if the plate being welded was so thic. that the bottom of the plate did not heat up.

3.2.4 T HE EQUATION FOR TEMPERATURE DISTRIBUTION IN THE SEMI - INFINITE PLATE

$hen the reflection terms are omitted the resulting equation for the temp distribution in the semi-infinite plate is T#T- )+ $here +#e-%.e- %/// /#02 !2 "21'/2 )#3p/2.

3.2.5 T HE EQUATION FOR HEATING AND COOLING RATES

IN THICK PLATES
4etallurgists are often interested in the heating and cooling rates of metals. These rates can be found anal!ticall! b! differentiating the equation for temperature with respect to time. $hen this is done the expression for rate of temp change in thic. plate is

3.2.

C ALCULATED TEMPERATURE DISTRIBUTION IN

ALUMINIUM
+quation 5 gi%es the temperature distribution about a fusion weld in a thic. plate that is infinitel! wide. The equation has been sol%ed for t!pical welding conditions utili"ed in the welding of 6'S aluminium allo! and mild steel 7 inch thic.. In fig , the isothermal temperature distribution is gi%en for a plate of 6'S being machine-welded. The heat source& an arc is tra%eling 8 inch per min and is drawing **, amp at (( %olts. These %alues are t!pical for the machine arc welding of 7 in )l plate. The isothermal lines ha%e been computed for a plane l!ing -.2 cm below the surface.