Calculation of thermal features in welding and additive manufacturing

Abstract

This paper summarizes multiple engineering expressions that enable the prediction of thermal magnitudes of interest associated with moving heat sources. The expressions use only fundamental parameters available before performing any experiments, and their calculation is algebraic, without the need for numerical methods. All expressions are based on the fundamental governing equations of heat transfer in the solid. The magnitudes predicted include maximum width and its location, maximum penetration, thickness of HAZ, maximum temperature and its location, leading and trailing edge of an isotherm, heating and cooling rate, aspect ratio of an isotherm, melting efficiency, cooling time from 800°C to 500°C, solidification time, and maximum distribution of a heat source to reach a target temperature. Parameters involved include heat source power and speed, thermal conductivity and diffusivity of the substrate material, temperature of interest and preheat or interpass temperature. Temperature-dependent properties are accounted for by the use of effective properties. The expressions proposed can be extended into sophisticated geometries for welding and specific additive manufacturing cases.