Fluid Flow Modeling in Welding Processes — Lesson 1

This lesson covers the finite element modeling of heat transfer and fluid flow analysis, particularly in the fusion rolling process. It explains the importance of fluid flow in the welding process and how to develop an API model by solving the governing equation and associated boundary conditions. The lesson also discusses the role of surface active elements in fluid flow and how they affect the welding process. It further delves into the governing equations associated with material flow and boundary conditions, and how to solve these using finite element formulation. The lesson also touches on the concept of free surface modeling in welding processes and the impact of surface active elements on the fusion zone shape. It concludes with a discussion on the implementation of finite element methods in fluid flow analysis.

Video Highlights

01:16 - Importance of surface active elements in fluid flow and their role in welding processes
13:57 - Explanation of how the presence of surface active elements in the liquid metal can significantly alter the weld penetration
35:12 - Implementation of finite element modeling in welding processes
53:55 - Penalty finite element method in fluid flow analysis

Key Takeaways

- Surface active elements, such as oxygen and sulfur, can alter the surface tension gradient and change the direction of fluid flow or metal flow field within the weld pool.
- The finite element modeling can be used to analyze heat transfer and fluid flow, particularly in the fusion rolling process.
- Fluid flow is essential in the welding process and can be influenced by surface active elements, which can also affect the surface tension force.
- In welding processes, energy transfer occurs from the arc, causing momentum transport within the molten pool, this is influenced by surface tension force and can be altered by surface active elements