Rhidiyan Waroko, 0806331935

Departemen Teknik Metalurgi dan Material

Universitas Indonesia

Homework

Heat Flow In Welding

2.1. In one welding experiment,50-mm-thick steel plates were joined using electro slag welding. The
current and voltage were 480A and 34V, respectively. The heat losses to the water-cooled copper
shoes and by radiation from the surface of the slag pool were 1275 and 375cal/s, respectively.
Calculate the heat source efficiency.
Answer :
Welding method : electro slag welding
Base metal : 50-mm-thick steel plate
Current : 480 A
Voltage : 34 V
Heat losses : 1275 cal/s to the water cooled copper shoes
375 cal/s by radiation from the surface of the slag pool
Heat source efficiency (h)=
Q
to base metaI
.t
veId
Q
nomnaI
.t
veId

=
(480 A .34 V)-((1275 caI+375 caI).4.184)
480 A .34 V
=
16320 ]-6093,6 ]
16320
= u.S77
= 57.7 %

2.2. It has been reported that the heat source efficiency in electro slag welding increases with
increasing thickness of the work piece. Explain why?
Answer :
Increasing a thickness of the work piece will increase size of weld pool, so it will increase the weld
metal volume. When that volume increases, it can make cooling rate decrease. Cooling rate
decrease can make heat distribution more restriction at weld area and make heat input more
focus at one spot area.

a. Consider the welding of 25.4-mm-thick steel plates. Do you prefer to apply Rosenthals two- or
three-dimensional heat flow equation for full-penetration electron beam welds? What about
bead-on-plate gastungsten arc welds?
b. Suppose you are interested in studying the solidification structure of the weld metal and you
wish to calculate the temperature distribution in the weld pool. Do you expect Rosenthals
equations to provide reliable thermal information in the pool? Why or why not?
c. In multi pass welding do you expect a higher or lower cooling rate in the first pass than in the
subsequent passes? Why?
2.3.
Answer :
a. For full penetration electron beam welds, I prefer to apply Rosenthals three dimensional heat
flow equation, because of its weld deep. EBW can produce weld with full penetration. For full
penetration at 25.4 mm thickness plate, thickness direction must be included for heat flow
analysis. For GTAW in plate, I prefer to choose two dimensional heat flow equation, because
GTAW will produce weld with no fully penetration and result larger size of HAZ.
b. Rosenthals equation can give information about temperature at one spot during welding
process. That information mean the initial temperature which effected by welding process.
With variable x and R in Rosenthals equation, it can describe large of T at R spot. Large of T
can give information about state of that spot during welding, melt or solid. I think Rosenthals
equation reliable to give thermal information for analysis solidification structure. Because
solidification structure just need information about initial temperature and cooling rate of that
piece.
c. Cooling rate at first pass is larger than subsequent pass, because when first pass, initial
temperature of work piece still ambient temperature, so there is large different from weld
metal temperature, and heat still distribute to whole of work piece. At subsequent pass, initial
temperature of work peaces is higher than ambient temperature, so the different between
weld metal and work peace is smaller than different of both at first pass, so cooling rate will
decrease.

2.4. Large aluminum sheets 1.6mm thick are butt welded using GTAW with alternating current. The
current, voltage, and welding speed are 100A, 10V and 2 mm/s, respectively. Calculate the peak
temperatures at distance of 1.0 and 2.0 mm from the fusion boundary. Assume 50% arc efficiency.
Answer :
Welding method : GTAW with AC
Current : 100 A
Voltage : 10 V
Welding speed : 2 mm/s
Thickness : 1.6 mm
Distance : 1.0 mm and 2.0 mm
Efficiency, h : 50 %

Adams equation for two dimension :
1
T
P
-T
o
=
4.13VYgpC
Q x h
+
1
T
m
-T
o
T
p
=
1

4.13VYgpC
Q x h
+
1
T
m
-T
o

+T
o

T
p,1mm
=
1
_
4.13 x 0.002
m
s
x 0.001 m x 2. x 10
6

J
m
3
K

100 A x 10 V x S0%
+
1
933 K-298 K
_
298 K
= 905.47 K
T
p,2mm
=
1
_
4.13 x 0.002
m
s
x 0.002m x 2. x 10
6

J
m
3
K

100 A x 10 V x S0%
+
1
933 K-298 K
_
298 K
= 880.23 K
2.5. Bead-on-plate welding of a thick section carbon steel is carried out using 200A, 20V and 2mm/s.
The preheat temperature and arc efficiency are 100C and 60%, respectively. Calculate the cross-
sectional area of the weld bead.
Answer :
Current : 200 A
Voltage : 20 V
Welding speed : 2 mm/s
Preheat temperature : 100
o
C
Arc efficiency : 60 %
For this case, it must be full penetration to analysis cross sectional area. So, the temperature at
the bottom of work piece must be Tm, 1800 K.
Rosenthals equation for two dimension :

2(T-T
o
)kg
Q
= exp
Vx
2u
K
o

Vr
2u

2 x 3.14 x (1800 K-373 K)x 41.0
J
msK
x (g)
200 A x 20 V x 60 %
= e
|0]

r = (x
2
+ y
2
)
1/2
1SS.u9SS g = 1
x=0, y=0, g = 0.006532 m = 0.257 in
r = 0

2.6. Calculate the thermal cycle at the top surface of a very thick carbon steel plate at 5mm away from
the centerline of the weld surface. The power of the arc is 2kW, the arc efficiency 0.7, the travel
speed 2mm/s, and the preheat temperature 100C!
Answer :
Thickness : 5 mm
Power : 2000 W
Arc efficiency : 0.7
Speed : 2 mm/s
Preheat temp. : 373 K
Rosenthals equation for three dimension :
2(T-T
o
)kR
Q
= exp
-V(R-x)
2u
T = (
Q
2kR
exp
-V(R-x)
2u
) + T
o

x = v. t T = (
Q
2kR
exp_
-V((25+Vt)
12
-Vt)
2u
_) + T
o

y = 5 mm, z = 0, R = (25 x 10
-6
+ (Vt)
2
)
1/2

T = _
2uuu } x 7u%
2 x S.14 x 41
}
msK
x x (2S x 1u
-6
+4 x 1u
-6
t)
12

exp
u.uu2(2S x 1u
-6
+4 x 1u
-6
t)
1
2 u.uu2t))
2 x 9.1 x 1u
-6
_ +S7S K
T =
5.43
(25 x 10
-6
+4 x 10
-6
t)
12

exp1u9.89(2S x 1u
-6
+ 4 x 1u
-6
t)
1
2
u.uu2t) + S7S K
From equation above, can be calculated the value of T in x second at x = Vt, y = 5 mm, z = 0 spot
away from the centerline of the weld surface :
t (at time) 1 2 3 4 5 6 7 8 9 10
T (Temperature) 1069 1025 943.6 865.3 800.2 747.7 705.5 671.3 643.1 619.5





0
200
400
600
800
1000
1200
0 20 40 60 80 100 120
T
e
m
p
e
r
a
t
u
r
e
,

T
Time, t
Thermal Cycle at 5 mm away from weld bead for
Carbon Steel