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The high amount of resource consumption of fusion welding processes offers the potential to reduce their environmental impact. While the driving forces are known froma qualitative perspective, the quantitative assessment of the crucial parameters is not a trivial task. Therefore, herein, a welding-specific methodology to utilize life cycle assessment as a tool for evaluating the environmental impact of fusion welding processes is presented. In this context, two welding processes, resistance spot welding and laser beam welding, are analyzed for two different use cases.
These comprise the welding of shear test specimens and a cap profile made of electrogalvanized sheets of DC 05þ ZE (1.0312) as representative of an automotive application. For both welding processes, the main influences on the resulting environmental impact categories are evaluated and compared. The requirements for ecological efficient welding processes are discussed and implemented.
The objective of this paper is to demonstrate a new simulation technique which allows fast and automatic generation of temperature fields as input for subsequent thermomechanical welding simulation. The basic idea is to decompose the process model into an empirical part based on neural networks and a phenomenological part that describes the physical phenomena. The strength of this composite modelling approach is the automatic calibration of mathematical models against experimental data without the need for manual interference by an experienced user. As an example for typical applications in laser beam and GMA-laser hybrid welding, it is shown that even 3D heat conduction models of a low complexity can approximate measured temperature fields with a sufficient accuracy. In general, any derivation of model fitting parameters from the real process adds uncertainties to the simulation independent of the complexity of the underlying phenomenological model. The modelling technique presented hybridises empirical and phenomenological models. It reduces the model uncertainties by exploiting additional information which keeps normally hidden in the data measured when the model calibration is performed against few experimental data sets. In contrast, here the optimal model parameter set corresponding to a given process parameter is computed by means of an empirical submodel based on relatively large set of experimental data. The approach allows making a contribution to an efficient compensation of modelling inaccuracies and lack of knowledge about thermophysical material properties or boundary conditions. Two illustrating examples are provided.
The paper presents bounded volume heat sources and the corresponding functional-analytical expressions for the temperature field. The power density distributions considered here are normal, exponential and parabolic. The sources model real heat sources like the welding arc, laser beam, electron beam, etc., the convection in the weld pool as well as the latent heat due to fusion and solidification. The parameters of the heat source models are unknown a priori and have to be evaluated by solving an inverse heat conduction problem. The functional-analytical technique for calculating 3D temperature fields in butt welding is developed. The proposed technique makes it possible to reduce considerably the total time for data input and solution. It is demonstrated with an example of laser beam welding of steel plates.