journal article·2013-06

Gas Metal Arc Welding Process Modeling and Prediction of Weld Microstructure in MIL A46100 Armor-Grade Martensitic Steel

M. Grujicic, A. Arakere, S. Ramaswami, J. S. Snipes, R. Yavari, C-F. Yen, B. A. Cheeseman, J. S. Montgomery

Publisher page

Abstract

A conventional gas metal arc welding (GMAW) butt-joining process has been modeled using a two-way fully coupled, transient, thermal-mechanical finite-element procedure. To achieve two-way thermal-mechanical coupling, the work of plastic deformation resulting from potentially high thermal stresses is allowed to be dissipated in the form of heat, and the mechanical material model of the workpiece and the weld is made temperature dependent. Heat losses from the deposited filler-metal are accounted for by considering conduction to the adjoining workpieces as well as natural convection and radiation to the surroundings. The newly constructed GMAW process model is then applied, in conjunction with the basic material physical-metallurgy, to a prototypical high-hardness armor martensitic steel (MIL A46100). The main outcome of this procedure is the prediction of the spatial distribution of various crystalline phases within the weld and the heat-affected zone regions, as a function of the GMAW process parameters. The newly developed GMAW process model is validated by comparing its predictions with available open-literature experimental and computational data.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Welding Techniques and Residual Stresses · Advanced Welding Techniques Analysis · Additive Manufacturing Materials and Processes

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (39)

Show source-provided references
1. M.G.H. Wells, R.K. Weiss, and J.S. Montgomery, “LAV armor plate study”, MTL TR 92–26, US Army Materials Technology Laboratory, Watertown, MA, 1992
2. A.D. Althouse, C.H. Turnquist, W.A. Bowditch, K.E. Bowditch, and M.A. Bowditch. Gas Metal Arc Welding, Modern Welding, 10th ed., Goodheart-Willcox Publisher, Tinley Park, IL, 2004, p 233–265.
3. W. Zhang, J.W. Elmer, and T. DebRoy, Modeling and Real Time Mapping of Phases During GTA Welding of 1005 Steel, Mater. Sci. Eng., A, 2002, 333, p 320–33510.1016/S0921-5093(01)01857-3 ↗
4. Ø. Grong, Metallurgical Modelling of Welding, 2nd ed., The Institute of Materials, London, 1997
5. K. Easterling, Introduction to the Physical Metallurgy of Welding, 2nd ed., Butterworth Heinemann, Boston, 1992
6. L.-E. Svensson, Control of Microstructures and Properties in Steel Arc Welds, CRC Press, Boca Raton, 1994
7. R. Mancini and C. Budde, Reaustenitisation in Fe-C Steels Revisited, Acta Mater., 1999, 47, p 2907–291110.1016/S1359-6454(99)00171-8 ↗
8. R.C. Reed, T. Akbay, Z. Shen, J.M. Robinson, and J.H. Root, Determination of Reaustenitisation Kinetics in a Fe-0.4C Steel Using Dilatometry and Neutron Diffraction, Mater. Sci. Eng., A, 1998, 256, p 152–16510.1016/S0921-5093(98)00800-4 ↗
9. J.H. Valentich, Tube Type Dilatometers: Applications From Cryogenic to Elevated Temperatures, Instrument Society of America, Research Triangle Park, NC, 1981
10. J. Haidar, A Theoretical Model for Gas Metal Arc Welding and Gas Tungsten Arc Welding. I, J. Appl. Phys., 1998, 84, p 3518–352910.1063/1.368527 ↗
11. J. Haidar, Prediction of Metal Droplet Formation in Gas Metal Arc Welding. II, J. Appl. Phys., 1998, 84, p 3530–354010.1063/1.368528 ↗
12. J. Haidar, An Analysis of Heat Transfer and Fume Production in Gas Metal Arc Welding. III, J. Appl. Phys., 1998, 85, p 3448–345910.1063/1.370500 ↗
13. J. Hu and H.L. Tsai, Heat and Mass Transfer in Gas Metal Arc Welding. Part I: The Arc, Int. J. Heat Mass Transf., 2007, 50, p 833–84610.1016/j.ijheatmasstransfer.2006.08.025 ↗
14. J. Hu and H.L. Tsai, Heat and Mass Transfer in Gas Metal Arc Welding. Part II: The Metal, Int. J. Heat Mass Transf., 2007, 50, p 808–82010.1016/j.ijheatmasstransfer.2006.08.026 ↗
15. S.J. Unfried, C.M. Garzón, and J.E. Giraldo, Numerical and Experimental Analysis of Microstructure Evolution During Arc Welding in Armor Plate Steels, J. Mater. Process. Technol., 2009, 209, p 1688–170010.1016/j.jmatprotec.2008.04.025 ↗
16. M. Grujicic, S. Ramaswami, J.S. Snipes, R. Yavari, A. Arakere, C.-F. Yen and B.A. Cheeseman, Computational Modeling of Microstructure Evolution in AISI 1005 Steel During Gas Metal Arc Butt Welding, J. Mater. Eng. Perform., 2012. doi: 10.1007/s11665-012-0402-110.1007/s11665-012-0402-1 ↗
17. MIL STD-A46100 Standard specification, 1983: Armor plate steel wrought high hardness
18. J.-O. Andersson, T. Helander, L. Höglund, P. Shi, and B. Sundman, Calphad-Based Thermocalc and Dictra Method, Calphad, 2002, 26, p 273–31210.1016/S0364-5916(02)00037-8 ↗
19. H.K.D.H. Bhadeshia, L.-E. Svensson, and B. Gretoft, A Model for the Development of Microstructure in Low-Alloy Steel (Fe-Mn-Si-C) Weld Deposits, Acta Metall., 1985, 33, p 1271–128310.1016/0001-6160(85)90238-X ↗
20. S.J. Jones and H.K.D.H. Bhadeshia, Kinetics of the Simultaneous Decomposition of Austenite into Several Transformation Products, Acta Mater., 1997, 45, p 2911–292010.1016/S1359-6454(96)00392-8 ↗
21. H. Matsuda and H.K.D.H. Bhadeshia, Kinetics of the Bainite Transformation, Proc. R. Soc. Lond. A, 2004, 460, p 1707–172210.1098/rspa.2003.1225 ↗
22. P. Kruger, On the Relation Between Non-isothermal and Isothermal Kolmogorov-Johnson-Mehl-Avrami Crystallization Kinetics, J. Phys. Chem. Solids, 1993, 54, p 1549–155510.1016/0022-3697(93)90349-V ↗
23. M. Grujicic and G. Haidemenopoulos, Treatment of Paraequilibrium, Thermodynamics in an AF1410 Steel Using the Thermo-calc Software and, Database, Calphad, 1988, 12, p 219–22410.1016/0364-5916(88)90002-8 ↗
24. M. Grujicic, Thermodynamics Aided Design of High Co-Ni Secondary Hardening Steels, Calphad, 1990, 14, p 49–5910.1016/0364-5916(90)90039-3 ↗
25. M. Grujicic, B. Pandurangan, C.-F. Yen, and B.A. Cheeseman, Modifications in the AA5083 Johnson-Cook Material Model for Use in Friction Stir Welding Computational Analyses, J. Mater. Eng. Perform., 2011. doi: 10.1007/s11665-011-0118-7 .10.1007/s11665-011-0118-7 ↗
26. M. Grujicic, G. Arakere, B. Pandurangan, J. M. Ochterbeck, C-.F. Yen, B. A. Cheeseman, A. P. Reynolds, and M. A. Sutton, Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys, J. Mater. Eng. Perform., 2011. doi: 10.1007/s11665-011-0069-z10.1007/s11665-011-0069-z ↗
27. M. Grujicic, G. Arakere, A. Hariharan, B. Pandurangan, C.-F.Yen, and B.A. Cheeseman, Two-level Weld-Material Homogenization Approach for Efficient Computational Analysis of Welded Structure Blast Survivability, J. Mater. Eng. Perform., 2010. doi: 10.1007/s11665-011-9876-510.1007/s11665-011-9876-5 ↗
28. M. Grujicic, G. Arakere, A. Hariharan, and B. Pandurangan, A Concurrent Product-development Approach for Friction-Stir Welded Vehicle-Underbody Structures, J. Mater. Eng. Perform., 2012, 21, p 437–44910.1007/s11665-011-9955-7 ↗
29. M. Grujicic, G. Arakere, B. Pandurangan, A. Hariharan, C.-F. Yen, B.A. Cheeseman, and C. Fountzoulas, Computational Analysis and Experimental Validation of the Ti-6Al-4V Friction Stir Welding Behavior, J. Eng. Manuf., 2010, 224, p 1–1610.1243/09544054JEM1750 ↗
30. M. Grujicic, G. Arakere, B. Pandurangan, A. Hariharan, C.-F. Yen, and B.A. Cheeseman, Development of a Robust and Cost-effective Friction Stir Welding Process for use in Advanced Military Vehicle Structures, J. Mater. Eng. Perform., 2011, 20, p 11–2310.1007/s11665-010-9650-0 ↗
31. M. Grujicic, G. Arakere, C.-F. Yen, and B.A. Cheeseman, Computational Investigation of Hardness Evolution During Friction-Stir Welding of AA5083 and AA2139 Aluminum Alloys, J. Mater. Eng. Perform., 2011, 20, p 1097–110810.1007/s11665-010-9741-y ↗
32. M. Grujicic, G. Arakere, H.V. Yalavarthy, T. He, C.-F. Yen, and B.A. Cheeseman, Modeling of AA5083 Material-Microstructure Evolution During Butt Friction-Stir Welding, J. Mater. Eng. Perform., 2010, 19, p 672–68410.1007/s11665-009-9536-1 ↗
33. M. Grujicic, T. He, G. Arakere, H.V. Yalavarthy, C.-F. Yen, and B.A. Cheeseman, Fully-Coupled Thermo-mechanical Finite-Element Investigation of Material Evolution During Friction-Stir Welding of AA5083, J. Eng. Manuf., 2010, 224, p 609–62510.1243/09544054JEM1750 ↗
34. G.R. Johnson and W.H. Cook, A Constitutive Model and Data for Metals Subjected to Large Strains, High Strain Rates and High Temperatures, Proceedings of the 7th International Symposium on Ballistics, 1983
35. ABAQUS Version 6.10EF, User Documentation, Dassault Systems, 2011.
36. MATLAB, The Language of Technical Computing, Version 8.0.0.783, R2012b. The MathWorks Inc., MA.
37. M. Gore, M. Grujicic, G.B. Olson, and M. Cohen, Thermally Activated Grain Boundary Unpinning, Acta Metall., 1989, 37, p 2849–285410.1016/0001-6160(89)90320-9 ↗
38. M. Grujicic and G.B. Olson, Dynamics of Martensitic Interfaces, Interface Sci., 1998, 6, p 155–16410.1023/A:1008676806550 ↗
39. M. Grujicic and N. Sankaran, Dispersed-Phase Martensitic Transformation Controlled Deformation Behavior of Two-Phase Metallic Materials, Int. J. Solids Struct., 1997, 34, p 4421–444610.1016/S0020-7683(97)00012-7 ↗