Gas Arc Welding FEA
Computational Analysis on Aluminum
Welding is considered one of the oldest forms of the additive manufacturing process. I had a chance to work on solving a problem of analyzing gas arc welding performed on aluminum material.
Project Overview
I successfully conducted a computational analysis of the gas arc welding process on aluminum, significantly reducing project costs by eliminating the need for extensive personnel training, equipment expenses, and trial-based experimentation. This simulation-driven approach saved thousands of dollars from the project budget while ensuring accurate and reliable results.
To model the welding process, I implemented Goldak's heat source model equations to create a moving heat source, simulating the thermal behavior of the weld pool. The simulation was executed using High-Performance Computing (HPC) with FORTRAN, ensuring precise and accelerated calculations.
Key Outcomes
By leveraging computational modeling, this research provided key insights and tangible benefits:
- Accurate prediction of temperature distribution and heat transfer in aluminum welding.
- Verification of the computational model against published experimental studies, ensuring its validity.
- Optimized experimental setup based on simulation data, improving efficiency and reducing trial-and-error.
This project provided a cost-effective and high-fidelity solution for understanding and optimizing gas arc welding processes, contributing to improved methodology and process efficiency.