Finite element model

Physics based modelling of welding processes is significant where experimental measurement of all intricate details is nearly impossible. Specifically the material flow in fusion welding or friction stir welding is difficult to measure. Hence, finite element tool can be used to model welding processes. In general, the models can be categorised as only thermal, thermo-mechanical, thermo-fluid or thermal-metallurgical-mechnaical. The interaction of the different heat source with substrate materials is often represented as "heat source model" in truely mathematical sense. Either user developed code or commercial software is used to develop different models associated with welding processes.

Heat source models in fusion welding (user defined code)

• Adaptive volumetric heat source (HSM 1)

• Egg-configuration heat source model (HSM 2)

• Avocado-shape heat source model (HSM 3)

• Arbitrary volumetric heat source model (HSM 4)

• Other heat source model (HSM, HSM A)

Finite element code developed related to welding processes

• Transient and steady-state heat transfer of fusion welding - P1, P2, P3

• Fluid flow in fusion welding (surface active elements) - P1, P2, P3, P4

• Residual stress estimation of fusion welding and solid state welding process - P1, P2

• Ultra-short pulse laser heating (Non-Fourier heat conduction using dual phase lag model) - P1, P2, P3, P4

• Resistance spot welding using dynamic contact resistance - P1

• Heat transfer in Friction stir welding

Finite element model using commercial software

• Surface and volumetric defects in friction stir welding - P1, P2, P3, P4

• Residual stress including the effect of phase transformation kinetics - P1, P2

• Induction welding - coupled thermal-electromagnetic model - P1

• Material deposition in additive manufacturing