Design, Modelling and Simulation

Arc welding modelling

CRRC QISHUYAN INSTITUTE CO., LTD. (Ge Jiaqi) / CSIRO (Tony Murphy)

Research summary

Metal welding is important in the manufacture of rolling stock, with the use of software that reliably predicts weld properties having the ability to save significant time and expense. CSIRO has developed modelling software that can provide critical information on a weld, including depth and shape of the weld and temperature distributions in the welded metal. This project developed a software module to use for welding rail components.

Start/end date

1 April 2018 to 31 March 2020

Total contracted budget (including in-kind)

$1,810,902

Key achievements

• A software module was developed for predicting welding parameters that give optimised quality and speed of welds in rail components.
• Graphs showing weld cross-sections, and slice and surface views of the weld in progress, were built into the software module.
• Validated models for arc welds for aluminium, magnesium and steel joints for butt, lap, T- and corner joints were developed and incorporated into the software module.
• Validated models for arc welding of steels with Ar/O₂ and Ar/CO₂ shielding gas were developed and incorporated into the software module.

Publications

Chen, F., Xiang, J., Thomas, D. and Murphy, A. Arc welding modelling software benchmarking for parameter optimisation, 13th International Conference on CFD in the Minerals and Process Industries, Melbourne, Australia, 2018, pp. 307–308 (2018).

Chen, F., Xiang, J., Thomas, D. and Murphy, A. MIG welding software benchmarking, IIW Document 212-1636-19, Annual Meeting of International Institute of Welding Study Group 212, Bratislava, Slovakia, 2019 (2019).

Chen, F., Xiang, J., Thomas, D. and Murphy, A. Model-based parameter optimization for arc welding process simulation, Math. Modell. 81 386–400 (2020).

Murphy, A., Chen, F., Xiang, J., Thomas, D and Feng, Y. Modelling the mushy zone in MIG welding, IIW Document 212-1634-19, Annual Meeting of International Institute of Welding Study Group 212, Bratislava, Slovakia, 2019 (2019).

Murphy, A., Chen, F., Xiang, J., Thomas, D. and Feng, Y. The mushy zone in a model of arc welding of aluminium alloys, 13th International Conference on CFD in the Minerals and Process Industries, Melbourne, Australia, 2018, pp. 224–225 (2018).

Murphy, A., Xiang, J., Park, H., Chen, F., Thomas, D., Feng, Y., Tanaka, K., Shigeta, M. and Tanaka, M. Metal vapour in arc welding, 5th International Symposium on Visualization in Joining & Welding Science through Advanced Measurements and Simulation & 8th International Conference of Welding Science and Engineering, Osaka, Japan, 2019, vol. 1, pp. 1–2 (2019).

Murphy, A., Xiang, J., Park, H., Chen, F., Thomas, D., Feng, Y., Tanaka, K., Shigeta, M., and Tanaka, M. Metal vapour in arc welding. Book of Abstracts, 21st Gaseous Electronics Meeting, Canberra, 2020.

Thomas, D., Murphy, A., Chen, F., Xiang. J. and Feng, Y. ArcWeld: A case study of the extensibility of software applications built using Workspace architecture, Proc. 23rd International Congress on Modelling and Simulation, Canberra, Australia, 2019, pp. 470–476 (2019).