A Monte Carlo model for 3D grain evolution during welding

Rodgers, Theron M.; Mitchell, John A.; Tikare, Veena

doi:10.1088/1361-651x/aa7f20

Title: A Monte Carlo model for 3D grain evolution during welding

Abstract

Welding is one of the most wide-spread processes used in metal joining. However, there are currently no open-source software implementations for the simulation of microstructural evolution during a weld pass. Here we describe a Potts Monte Carlo based model implemented in the SPPARKS kinetic Monte Carlo computational framework. The model simulates melting, solidification and solid-state microstructural evolution of material in the fusion and heat-affected zones of a weld. The model does not simulate thermal behavior, but rather utilizes user input parameters to specify weld pool and heat-affect zone properties. Weld pool shapes are specified by Bezier curves, which allow for the specification of a wide range of pool shapes. Pool shapes can range from narrow and deep to wide and shallow representing different fluid flow conditions within the pool. Surrounding temperature gradients are calculated with the aide of a closest point projection algorithm. Furthermore, the model also allows simulation of pulsed power welding through time-dependent variation of the weld pool size. Example simulation results and comparisons with laboratory weld observations demonstrate microstructural variation with weld speed, pool shape, and pulsed-power.

Authors:

^[1]; Mitchell, John A. ^[1]; Tikare, Veena ^[1]

Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Publication Date:: Fri Aug 04 00:00:00 EDT 2017

Research Org.:: Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Sponsoring Org.:: USDOE National Nuclear Security Administration (NNSA)

OSTI Identifier:: 1374751

Report Number(s):: SAND-2017-8231J
Journal ID: ISSN 0965-0393; 655911

Grant/Contract Number:: AC04-94AL85000

Resource Type:: Accepted Manuscript

Journal Name:: Modelling and Simulation in Materials Science and Engineering

Additional Journal Information:: Journal Volume: 25; Journal Issue: 6; Journal ID: ISSN 0965-0393

Publisher:: IOP Publishing

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; 97 MATHEMATICS AND COMPUTING; welding; grain growth; Potts Monte Carlo; solidification

Citation Formats


                    Rodgers, Theron M., Mitchell, John A., and Tikare, Veena. A Monte Carlo model for 3D grain evolution during welding.  United States: N. p., 2017. 
Web.  doi:10.1088/1361-651x/aa7f20.

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                    Rodgers, Theron M., Mitchell, John A., & Tikare, Veena. A Monte Carlo model for 3D grain evolution during welding.  United States.  https://doi.org/10.1088/1361-651x/aa7f20

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                    Rodgers, Theron M., Mitchell, John A., and Tikare, Veena. Fri .  
"A Monte Carlo model for 3D grain evolution during welding".  United States.  https://doi.org/10.1088/1361-651x/aa7f20.  https://www.osti.gov/servlets/purl/1374751.

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@article{osti_1374751,

  title        = {A Monte Carlo model for 3D grain evolution during welding},

  author       = {Rodgers, Theron M. and Mitchell, John A. and Tikare, Veena},

  abstractNote = {Welding is one of the most wide-spread processes used in metal joining. However, there are currently no open-source software implementations for the simulation of microstructural evolution during a weld pass. Here we describe a Potts Monte Carlo based model implemented in the SPPARKS kinetic Monte Carlo computational framework. The model simulates melting, solidification and solid-state microstructural evolution of material in the fusion and heat-affected zones of a weld. The model does not simulate thermal behavior, but rather utilizes user input parameters to specify weld pool and heat-affect zone properties. Weld pool shapes are specified by Bezier curves, which allow for the specification of a wide range of pool shapes. Pool shapes can range from narrow and deep to wide and shallow representing different fluid flow conditions within the pool. Surrounding temperature gradients are calculated with the aide of a closest point projection algorithm. Furthermore, the model also allows simulation of pulsed power welding through time-dependent variation of the weld pool size. Example simulation results and comparisons with laboratory weld observations demonstrate microstructural variation with weld speed, pool shape, and pulsed-power.},

  doi          = {10.1088/1361-651x/aa7f20},

  journal      = {Modelling and Simulation in Materials Science and Engineering},

  number       = 6,

  volume       = 25,

  place        = {United States},

  year         = {Fri Aug 04 00:00:00 EDT 2017},

  month        = {Fri Aug 04 00:00:00 EDT 2017}

}

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Works referencing / citing this record:

Modeling analysis of the effect of laser transverse speed on grain morphology during directed energy deposition process
journal, May 2019

Li, Wei; Soshi, Masakazu
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Study of the effect of growth kinetic and nucleation law on grain structure simulation during gas tungsten arc welding of Cu-Ni plate
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Welding in the World, Vol. 63, Issue 3
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Title: A Monte Carlo model for 3D grain evolution during welding

Abstract

Citation Formats

Measurements and Monte Carlo simulation of grain growth in the heat-affected zone of Ti–6Al–4V welds journal, March 2004

Computer simulation of grain growth—I. Kinetics journal, May 1984

Grain topology in Ti–6Al–4V welds—Monte Carlo simulation and experiments journal, July 2004

Three-dimensional monte carlo simulation of grain growth in the heat-affected zone of a 2.25Cr-1Mo steel weld journal, June 2000

Crystal growth during keyhole mode laser welding journal, July 2017

Welding: Solidification and microstructure journal, June 2003

Evolution of solidification texture during additive manufacturing journal, November 2015

Simulation of the columnar-to-equiaxed transition in directionally solidified Al–Cu alloys journal, February 2005

Three-dimensional simulation of grain growth in a thermal gradient with non-uniform grain boundary mobility journal, September 2008

Microstructural refinement of weld fusion zones in α–β titanium alloys using pulsed current welding journal, April 1999

Phase field investigation of dendrite growth in the welding pool of aluminum alloy 2A14 under transient conditions journal, February 2014

Weld Metal Grain Structure and Mechanical Properties of a Th-Doped Ir-0.3 Pct W Alloy (DOP-26) journal, June 1982

The computer simulation of microstructural evolution journal, September 2001

3D Coupled Cellular Automaton (CA)–Finite Element (FE) Modeling for Solidification Grain Structures in Gas Tungsten Arc Welding (GTAW) journal, January 2014

Multiscale Modeling of Transport Phenomena and Dendritic Growth in Laser Cladding Processes journal, July 2011

Multi-scale modeling of solidification and microstructure development in laser keyhole welding process for austenitic stainless steel journal, February 2015

Analysis of multi-phase interaction and its effects on keyhole dynamics with a multi-physics numerical model journal, July 2014

Simulation of metal additive manufacturing microstructures using kinetic Monte Carlo journal, July 2017

A novel integrated model combining Cellular Automata and Phase Field methods for microstructure evolution during solidification of multi-component and multi-phase alloys journal, July 2011

Simulation of grain morphologies and competitive growth in weld pool of Ni–Cr alloy journal, December 2009

Predicting Mesoscale Microstructural Evolution in Electron Beam Welding journal, March 2016

The morphological evolution of the axial structure and the curved columnar grain in the weld journal, December 2015

Optimisation of pulse frequency in pulsed current gas tungsten arc welding of aluminium–lithium alloy sheets journal, January 1998

Modeling of fundamental phenomena in welds journal, March 1995

Microstructure analysis of AZ31 magnesium alloy welds using phase-field models journal, September 2012

Three-dimensional modeling of grain structure evolution during welding of an aluminum alloy journal, March 2017

Free surface flow and heat transfer in conduction mode laser welding journal, December 1988

Simulation of weld solidification microstructure and its coupling to the macroscopic heat and fluid flow modelling journal, December 2003

Numerical simulation of equiaxed grain formation in weld solidification journal, January 2003

Computational Contact Mechanics book, January 2006

Modeling analysis of the effect of laser transverse speed on grain morphology during directed energy deposition process journal, May 2019

Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties journal, October 2019

Study of the effect of growth kinetic and nucleation law on grain structure simulation during gas tungsten arc welding of Cu-Ni plate journal, March 2019

Measurements and Monte Carlo simulation of grain growth in the heat-affected zone of Ti–6Al–4V welds
journal, March 2004

Computer simulation of grain growth—I. Kinetics
journal, May 1984

Grain topology in Ti–6Al–4V welds—Monte Carlo simulation and experiments
journal, July 2004

Three-dimensional monte carlo simulation of grain growth in the heat-affected zone of a 2.25Cr-1Mo steel weld
journal, June 2000

Crystal growth during keyhole mode laser welding
journal, July 2017

Welding: Solidification and microstructure
journal, June 2003

Evolution of solidification texture during additive manufacturing
journal, November 2015

Simulation of the columnar-to-equiaxed transition in directionally solidified Al–Cu alloys
journal, February 2005

Three-dimensional simulation of grain growth in a thermal gradient with non-uniform grain boundary mobility
journal, September 2008

Microstructural refinement of weld fusion zones in α–β titanium alloys using pulsed current welding
journal, April 1999

Phase field investigation of dendrite growth in the welding pool of aluminum alloy 2A14 under transient conditions
journal, February 2014

Weld Metal Grain Structure and Mechanical Properties of a Th-Doped Ir-0.3 Pct W Alloy (DOP-26)
journal, June 1982

The computer simulation of microstructural evolution
journal, September 2001

3D Coupled Cellular Automaton (CA)–Finite Element (FE) Modeling for Solidification Grain Structures in Gas Tungsten Arc Welding (GTAW)
journal, January 2014

Multiscale Modeling of Transport Phenomena and Dendritic Growth in Laser Cladding Processes
journal, July 2011

Multi-scale modeling of solidification and microstructure development in laser keyhole welding process for austenitic stainless steel
journal, February 2015

Analysis of multi-phase interaction and its effects on keyhole dynamics with a multi-physics numerical model
journal, July 2014

Simulation of metal additive manufacturing microstructures using kinetic Monte Carlo
journal, July 2017

A novel integrated model combining Cellular Automata and Phase Field methods for microstructure evolution during solidification of multi-component and multi-phase alloys
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Simulation of grain morphologies and competitive growth in weld pool of Ni–Cr alloy
journal, December 2009

Predicting Mesoscale Microstructural Evolution in Electron Beam Welding
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The morphological evolution of the axial structure and the curved columnar grain in the weld
journal, December 2015

Optimisation of pulse frequency in pulsed current gas tungsten arc welding of aluminium–lithium alloy sheets
journal, January 1998

Modeling of fundamental phenomena in welds
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Microstructure analysis of AZ31 magnesium alloy welds using phase-field models
journal, September 2012

Three-dimensional modeling of grain structure evolution during welding of an aluminum alloy
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Free surface flow and heat transfer in conduction mode laser welding
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Simulation of weld solidification microstructure and its coupling to the macroscopic heat and fluid flow modelling
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Numerical simulation of equiaxed grain formation in weld solidification
journal, January 2003

Computational Contact Mechanics
book, January 2006

Modeling analysis of the effect of laser transverse speed on grain morphology during directed energy deposition process
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