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Heat Flow.ppsx

The document discusses the thermal conditions in welding, focusing on heat input, energy transfer efficiency, and melting efficiency. It provides equations for calculating energy input, peak temperatures, cooling rates, and the effects of preheat and plate thickness on these parameters. The information is essential for controlling microstructure and avoiding undesirable phases in welded materials.

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12 views28 pages

Heat Flow.ppsx

The document discusses the thermal conditions in welding, focusing on heat input, energy transfer efficiency, and melting efficiency. It provides equations for calculating energy input, peak temperatures, cooling rates, and the effects of preheat and plate thickness on these parameters. The information is essential for controlling microstructure and avoiding undesirable phases in welded materials.

Uploaded by

chudrimon
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Heat Input and

Heat flow in Welding


Different thermal conditions in and near
welding - To control microstructure

 The distribution of maximum or peak


temperatures in the weld heat affected zone
(HAZ)
 Cooling rates in the weld metal and in the
HAZ
 The solidification rate of the weld metal
Energy Input

Quantity of energy applied per unit length of weld (J/m)

The energy input for a traveling heat source is computed as the


ratio of the total heating power of the heat source in watts to its
travel velocity

P
H
v

H = Energy input, J/mm


P = Total power of heat source, W
v = Travel velocity of heat source, mm/s
If the heat source is an arc, the energy input can be
expressed to a first approximation

VI
H
v

H = Energy input, J/mm


V = Welding arc voltage, volts (V)
I = Welding arc current, A
v = Travel velocity of heat source, mm/s

Is all arc energy is effectively transferred to metal, What is its efficiency?


Net energy input, Hnet
f1 P f1VI
H net  f1 H  
v v

f1 = Heat transfer efficiency of


the source (heat actually
transferred to the workpiece
divided by the total heat
generated by the heat source)
Melting efficiency

Melting efficiency denotes the fraction of the net energy


input (Hnet ) that actually melts metal

Can be found out from


weld x-section

Aw  Am  Ar

Aw = Cross-sectional area of the weld metal


Am = Cross-sectional area of the base metal that was melted
Ar = Cross-sectional area of the added filler metal
A specific theoretical quantity of heat is required to melt a given
volume of metal (from ambient temperature). This theoretical
quantity of heat is a property of the metal or alloy known as the
melting enthalpy, Q. It is obtained by adding
(1) the heat required to elevate the temperature of the solid metal
to its melting point
(2) the heat required to convert a solid to liquid at the melting point
(the heat of fusion)

Approximate expression for Q is

(Tm  273) 2
Q
3 105
Q = Welding enthalpy, J/mm3
Tm = Melting temperature of the metal, oC
The melting efficiency (f2) - the theoretical quantity of heat
required to melt the weld deposit per unit length divided by the net
energy input

QAw QAwv QAwv


f2   
H net f1 P f1VI

P = 3823 W; v = 10 P = 10170 W; v =
mm/s; and H = 383 26 mm/s; and H =
J/mm. 391 J/mm.
Peak temperature equation

For a single pass, full penetration butt weld in sheet or plate


Distribution of peak temperatures in the base metal adjacent to the weld

1 4.13 C t Y 1
 
T p  T0 H net Tm  T0
Tp= Peak or maximum temperature in oC at a distance (mm),
from the weld fusion boundary
T0= Initial uniform temperature of the sheet or plate, oC
Tm= Melting (liquidus) temperature, oC
Hnet= Net energy input
ρ = Density of material, g/mm3
C = Specific heat of solid metal J/g.oC
t = Thickness of sheet or plate, mm
Y = distance from weld fusion boundary
Peak temperature equation can be used
 Determination of peak temperatures at specific locations in the HAZ
 Estimating the width of the HAZ
 Showing the effect of preheat on the width of the HAZ
Width of HAZ
Outer extremities must be clearly
identified with specific peak temperatures

1.
For plain carbon steel – distinct etch
boundary corresponding to a peak
temperature of 730oC

2.
For a quenched and tempered (@
430oC) steel
Any region heated above tempering
temperature is over-tempered
therefore heat affected
Peak temperature equation also suggest that
Width of HAZ is directly proportional to the net energy input
Distribution of peak temp.

1600

1500

1400

1300

1200
Tempearture

1100

1000

900

800

700

600

500

400
0 1 2 3 4 5 6 7 8
Distance from fusion line

Hnet = 720 J/mm To = 25C Hnet = 1200 J/mm To = 25C Hnet = 720 J/mm To = 200C
Cooling rates

• Varies with position and time


• Use to calculate preheat requirements
Determine the cooling rate on the centre line of the weld
at the instant the metal is passing through a particular
temperature of interest, Tc

In steels, pearlite nose temperature


Tc = 550oC

Very important for steels – to avoid formation of martensite


Cooling rate for
Thick plate requiring several passes (more than six)

2 k (Tc  T0 ) 2
R
H net

R = the cooling rate at a point on the weld centerline, oC/s, at


just that moment when the point is cooling past the
temperature of interest, Tc
Tc = The temperature at which the cooling rate is calculated
k = thermal conductivity of the metal, J/mm .s oC
Cooling rate for
Thin plate requiring
fewer than four
passes

2
 t 
R 2 k C   (Tc  T0 ) 3
 H net 
What is thick and thin?
Thick plate Eq. – when heat flow is 3-D
Thin plate Eq. – apply to any single pass full penetration welding process
Dimensionless quantity
Relative plate thickness

 C (Tc  T0 )
 t
H net

Thick plate Eq. – when τ is greater than 0.9


and
Thin plate Eq. – when τ is less than 0.6
Effect of To on cooling rate Reduces cooling rate

Determination of critical cooling rate –


to avoid formation of martensite

Hard martensitic structure is associated


with cracking under the influence of
thermal stresses in the presence of
hydrogen

In steels, pearlite nose temperature


Tc = 550oC
Typical weld thermal cycles
Thermal cycle in HAZ – Peak temperature as a function of
distance from weld centerline Plate thickness = 13 mm
Energy input = 3940 J/mm
Initial plate temp. = 27oC
1. Peak temp. decreases
rapidly with increasing
distance from the weld
centerline

2. The time reqd. to reach


peak temp. increases
with increasing distance
from the weld centerline

3. The rate of heating and


rate of cooling both
decreases with
increasing distance from
the weld centerline
Energy Preheat Distance from weld centerline to
input temp. point heated to:
J/mm o
C 1480oC 870oC 705oC

3940 27 9.4 13.2 15.5

3940 260 9.4 15.2 20.6

1970 27 7.4 9.1 9.4

1970 260 7.4 9.4 10.7


Peak temperature distribution in HAZ
Effect of energy input and preheat temperature
1. For a given preheat
temperature, increasing the
energy input causes
increase in the time of
exposure to temperatures
near the peak temperature
and causes a decrease in
the cooling rate

2. For a given energy input,


increasing the preheat
temperature decreases the
cooling rate, but does not
significantly influence the
time of exposure to temp.
near the peak temperature
Peak temperature distribution in HAZ
Effect of energy input and preheat temperature

Energy Preheat Peak Time above Cooling rate at


input temp.oC temp. 1095oC (s) 650oC (oC/s)
J/mm
3940 27 1365 16.5 4.4

3940 260 1365 17 1.4

1970 27 1365 5 14

1970 260 1365 5 4.4


Effect of plate thickness and weld geometry

The cooling rate tends


to increase with an
increase in plate
thickness

Time at elevated
temperature tends to
decrease with an
increase in plate
thickness

Heat flow pattern changes from 2-D in


thin plate to 3-D in thick plate

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