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Title: An integrated model for optimizing weld quality

Abstract

Welding has evolved in the last few decades from almost an empirical art to an activity embodying the most advanced tools of, various basic and applied sciences. Significant progress has been made in understanding the welding process and welded materials. The improved knowledge base has been useful in automation and process control. In view of the large number of variables involved, creating an adequately large database to understand and control the welding process is expensive and time consuming, if not impractical. A recourse is to simulate welding processes through a set of mathematical equations representing the essential physical processes of welding. Results obtained from the phenomenological models depend crucially on the quality of the physical relations in the models and the trustworthiness of input data. In this paper, recent advances in the mathematical modeling of fundamental phenomena in welds are summarized. State of the art mathematical models, advances in computational techniques, emerging high performance computers, and experimental validation techniques have provided significant insight into the fundamental factors that control the development of the weldment. Current status and scientific issues in heat and fluid flow in welds, heat source metal interaction, and solidification microstructure are assessed. Future research areas of majormore » importance for understanding the fundamental phenomena in weld behavior are identified.« less

Authors:
;  [1]; ;  [2]
  1. Oak Ridge National Lab., TN (United States)
  2. Concurrent Technologies Corp., Johnstown, PA (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab., TN (United States)
Sponsoring Org.:
USDOE, Washington, DC (United States)
OSTI Identifier:
87854
Report Number(s):
CONF-9509118-6
ON: DE95013220
DOE Contract Number:
AC05-84OR21400
Resource Type:
Conference
Resource Relation:
Conference: 7. Conference on modeling of casting, welding and advanced solidification processes, London (United Kingdom), 10-15 Sep 1995; Other Information: PBD: [1995]
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 99 MATHEMATICS, COMPUTERS, INFORMATION SCIENCE, MANAGEMENT, LAW, MISCELLANEOUS; WELDING; WELDED JOINTS; COMPUTERIZED SIMULATION; QUALITY CONTROL; PROCESS CONTROL

Citation Formats

Zacharia, T., Radhakrishnan, B., Paul, A.J., and Cheng, C. An integrated model for optimizing weld quality. United States: N. p., 1995. Web.
Zacharia, T., Radhakrishnan, B., Paul, A.J., & Cheng, C. An integrated model for optimizing weld quality. United States.
Zacharia, T., Radhakrishnan, B., Paul, A.J., and Cheng, C. Thu . "An integrated model for optimizing weld quality". United States. doi:. https://www.osti.gov/servlets/purl/87854.
@article{osti_87854,
title = {An integrated model for optimizing weld quality},
author = {Zacharia, T. and Radhakrishnan, B. and Paul, A.J. and Cheng, C.},
abstractNote = {Welding has evolved in the last few decades from almost an empirical art to an activity embodying the most advanced tools of, various basic and applied sciences. Significant progress has been made in understanding the welding process and welded materials. The improved knowledge base has been useful in automation and process control. In view of the large number of variables involved, creating an adequately large database to understand and control the welding process is expensive and time consuming, if not impractical. A recourse is to simulate welding processes through a set of mathematical equations representing the essential physical processes of welding. Results obtained from the phenomenological models depend crucially on the quality of the physical relations in the models and the trustworthiness of input data. In this paper, recent advances in the mathematical modeling of fundamental phenomena in welds are summarized. State of the art mathematical models, advances in computational techniques, emerging high performance computers, and experimental validation techniques have provided significant insight into the fundamental factors that control the development of the weldment. Current status and scientific issues in heat and fluid flow in welds, heat source metal interaction, and solidification microstructure are assessed. Future research areas of major importance for understanding the fundamental phenomena in weld behavior are identified.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Thu Jun 01 00:00:00 EDT 1995},
month = {Thu Jun 01 00:00:00 EDT 1995}
}

Conference:
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  • It has been shown previously that the use of a mathematical model to predict the inherent fluid flow, heat transfer, free surface profiles and other associated phenomena during welding leads to a better understanding and, therefore, control of the welding process. Unfortunately many of the models available today are primarily research codes and, therefore, do not serve as design tools for the production welding engineer. In the current investigation, WELDER -- a three dimensional, transient mathematical model, has been integrated with a framework based on the Rational Product & Process Design (R{center_dot}P{sup 2}{center_dot}D{sub sm}){sup +} methodology to create a truemore » design tool aimed towards use by engineers. This highly interactive and graphic tool simulates the welding process from the start to finish, and provides the user with capabilities to view the progression of welding and the associated heating and cooling of the base plate. In addition, analysis modules analyze the temperature profiles to predict residual stresses and evolving microstructures.« less
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  • Abstract not provided.
  • The Salt Lake City Area (SLCA) office of the Western Area Power Administration (Western) is responsible for marketing the capacity and energy generated by the Colorado Storage, Collbran, and Rio Grande hydropower projects. These federal resources are collectively called the Salt Lake City Area Integrated Projects (SLCA/IP). In recent years, stringent operational limitations have been placed on several of these hydropower plants including the Glen Canyon Dam, which accounts for approximately 80% of the SLCA/IP resources. Operational limitations on SLCA/IP hydropower plants continue to evolve as a result of decisions currently being made in the Glen Canyon Dam Environmental Impactmore » Statement (EIS) and the Power Marketing EIS. To analyze a broad range of issues associated with many possible future operational restrictions, Argonne National Laboratory (ANL), with technical assistance from Western has developed the Hydro LP (Linear Program) Model. This model simulates hourly operations at SLCA/IP hydropower plants for weekly periods with the objective of maximizing Western`s net revenues. The model considers hydropower operations for the purpose of serving SLCA firm loads, loads for special projects, Inland Power Pool (IPP) spinning reserve requirements, and Western`s purchasing programs. The model estimates hourly SLCA/IP generation and spot market activities. For this paper, hourly SLCA/IP hydropower plant generation is simulated under three operational scenarios and three hydropower conditions. For each scenario an estimate of Western`s net revenue is computed.« less
  • The Salt Lake City Area (SLCA) office of the Western Area Power Administration (Western) is responsible for marketing the capacity and energy generated by the Colorado River Storage, Collbran, and Rio Grande hydropower projects. These federal resources are collectively called the Salt Lake City Area Integrated Projects (SLCA/IP). In recent years, stringent operational limitations have been placed on several of these hydropower plants including the Glen Canyon Dam, which accounts for approximately 80% of the SLCA/IP resources. Operational limitations on SLCA/IP hydropower plants continue to evolve as a result of decisions currently being made in the Glen Canyon Dam Environmentalmore » Impact Statement (EIS) and the Power Marketing EIS. The Hydro LP (Linear Program) model, which was developed by Argonne National Laboratory (ANL), was used to analyze a broad range of issues associated with many possible future operational restrictions at SLCA/IP power plants. With technical assistance from Western, the Hydro LP model was configured to simulate hourly power plant operations for weekly periods with the objective of maximizing Western`s net revenues. The model considers hydropower operations for the purpose of serving SLCA firm loads, loads for special projects, Inland Power Pool (IPP) operating reserve requirements, and Western`s purchasing programs. The model estimates hourly SLCA/IP generation and spot market activities. For this paper, hourly SLCA/IP hydropower plant generation was simulated under three operational scenarios and three hydropower conditions. For each scenario an estimate of Western`s net revenue was computed.« less