FEM Modeling of EBW and RSW — Lesson 1

This lesson covers the finite element modeling of electron beam and resistance welding processes. It delves into the heat source model related to welding processes, the similarities between keyhole mode laser link process and electronic welding process, and the finite element modeling of electron beam welding process. The lesson also discusses the electron beam welding process in detail, including its principles, how it works, and its advantages. It further explores the challenges associated with electron beam welding, particularly when joining dissimilar materials. The lesson concludes with an in-depth look at the resistance welding process, its principles, and how to model it using finite element analysis.

Video Highlights

01:34 - Electron beam welding process and its high energy density
04:58 - Deflection of the electron beam using magnetic fields
08:15 - Explanation of the high precision and cost of the electron beam welding process
19:25 - Modeling of the resistance welding process
36:42 - Difficulties in separating individual resistance components in resistance spot welding
45:45 - Influence of the electrode holding time in the resistance welding process

Key Takeaways

- Electron beam welding process and keyhole mode laser link process have similar modeling approaches.
- Electron beam welding process is conducted under vacuum, which eliminates contamination from the atmospheric environment.
- The electron beam welding process can be affected by the CIVAC effect, which can cause the beam to deflect towards one side of the material.
-. Resistance welding process is commonly used in the automobile industry, but it faces challenges such as the presence of coating which can induce a constant magnitude of resistance at the contact surface.
- Finite element modeling can be used to understand and predict the behavior of both electron beam and resistance welding processes.