## General Mechanical

Topics relate to Mechanical Enterprise, Motion, Additive Print and more

#### Moving heat flux welding simulation

• aleM2
Subscriber

Hello everybody,

I am trying to perform a welding simulation. My inputs are a power of 2800 W and and a beam radius of 0.2mm.
Firstly, I am making a simple example with 2 cylinders and I am using the moving heat source extension where I set up a velocity of 10mm/s and a power of 22000W/mm2. As boundary condition I use a radiative boundary with a coefficient of 0,3.
Still I am not able to find a physical result. I get temperatures above 10000 degrees and I don't know how to solve this issue. Do you have any suggestion?

• Sampat Kumar
Ansys Employee

Hi
Have you verified your input power and the heat flux you provided in the moving heat source? First I would suggest checking the unit and power-to-heat flux conversion calculation. How much temperature you are expecting?
verify these points.
1. Conversion of power to heat Flux calculation and the unit.
2. Velocity and the unit

Regards,
Sampat

• aleM2
Subscriber

Hello,

The power is given and it's 2800W and to transform to heat flux ai simply divided the power for the area of the beam which is 3,14x0,2x0,2 and this is how I end up to 22000 W/mm2.
the units of the speed is also correct and it's 10mm/s.

• Sampat Kumar
Ansys Employee

Hi
Thanks for the information.
Are you verifying any research documents, or what is the source of these data? How much temperature are you expecting? What material has been assigned to the cylinder? Please let me know a little bit of detail about the data and background of your analysis. Is this temperature developed at a single point in the model?

Regards,
Sampat

• Al Ger
Subscriber

The source of the power and the beam radius are coming from a real welding electron beam machine.
The material that I've currently used is Inconel but I've tried also with the standard steel from ansys.
i don't have a temperature reference for the melting pool but I have some measurements 5mm away from the welding and they should reach around 200 degrees.
I get these very higher temperatures not only at 1 single node but distributed over a larger area.
you can see an example attached where I repeated the same calculation but this time with a heat flux of 700W/mm2 and a beam radius of 1mm.

• Sampat Kumar
Ansys Employee

Hi
Thanks for the information. Please let me know of any reference documents or experimental data for this numerical value of heat flux and beam radius that you have followed.
Please let me know what is the reference document for this data that you have taken the heat flux of 22000 W/mm2 with a beam radius of 0.2 mm and a 10mm/sec velocity. Have you performed any experiments with these parameters on the Inconel material? Do you have any reference documents for these data, published papers, or authentic material? I am a little bit skeptical about this heat flux of 22000 W/mm2 with a radius of 0.2mm data.

If you have followed any research paper or authentic material then have you verified which numerical formula they used to calculate the Heat flux and power? Please let me know.

The temperature you have obtained in the attached picture is maximum at the corner or the same at every place as the moving heat source moves from one point to another.

Regards,
Sampat

• Yolanda Gutierrez Diego
Subscriber

Hi,

I am trying to do the same but I am not able to find the moving heat flux ACT, could somebody tell me where is available to download?

Thanks

• Sampat Kumar
Ansys Employee

You can find it in the Ansys Store catalog.

Regards,
sampat