Self-consistent modelling of arc, material transfer and seam structure in gas metal arc welding

该项目的目的是开发、验证和应用一个过程模型，用于对气体金属弧焊的最终连接区域进行数值描述，包括电弧中的所有相关物理过程以及导线电极和母材处的熔体。计算应在物理上自洽，并依赖于工艺参数。它应该能够对最终的渗透轮廓、接缝结构和进入母材的热量输入进行有根据的陈述。所开发的过程模型满足工业4.0对所有连接过程完全可建模性的要求。为了保证过程模型具有较高的信息价值，同时考虑到相关子过程的不同时间尺度，将液滴分离模型与熔池模型依次耦合。采用液滴分离模型计算源项，实现了电弧和熔池中材料传递的特性，实现了子模型的组合。在项目的第一部分，将扩大现有的液滴分离和焊接池模型，以实现物理上自一致和时间效率的气体金属弧焊建模。在后续的模型应用过程中，将决定所开发的建模方法是否可以转移到其他实际相关的焊接任务和材料中。所开发的工艺模型能够详细分析气体金属弧焊的因果链，以及在广泛的参数范围内产生的焊缝的数值可预测性，从而能够确定气体金属弧焊工艺本身以及所使用的设备的物理发展。

The aim of the project is to develop, validate and apply a process model for the numerical description of the resulting joining zone of gas metal arc welding including all relevant physical processes in the arc as well as the melts at the wire electrode and parent material. The calculation should be physically self-consistent and dependant on the process parameters. It should enable well-founded statements regarding the resulting penetration profile, seam structure and heat input into the parent material. The developed process model meets the requirements of the industry for complete modelability of all joining processes as part of industry 4.0. In order to guarantee a high informative value of the process model while simultaneously taking into account the different time scales of the relevant sub-processes, a model of droplet detachment is sequentially coupled with a weld pool model. The combination of the sub models is achieved by implementing the characteristics of the arc and the material transfer in the weld pool model by source terms, which are calculated using the droplet detachment model. In the first part of the project, existing models of droplet detachment and weld pool will be enlarged to enable physically self-consistent and time-efficient modelling of gas metal arc welding. In the course of the subsequent model application, it will be determined whether the developed modelling approach can be transferred to other welding tasks and materials of practical relevance. The developed process model enables a detailed analysis of the cause and effect chain in gas metal arc welding as well as the numerical predictability of the resulting weld in a wide range of parameters, thus enabling a physically determined development of the gas metal arc welding process itself as well as the equipment used.