About this Abstract |
| Meeting |
MS&T26: Materials Science & Technology
|
| Symposium
|
Computational Materials for Qualification and Certification
|
| Presentation Title |
Integrated Modeling of Solidification Cracking in Fusion Welding of High-Strength Aluminum: Multi-Criteria Analysis Under Variable Restraints |
| Author(s) |
Zenan Zhang, Paul Blackhurst, Boyd Panton, Wei Zhang |
| On-Site Speaker (Planned) |
Zenan Zhang |
| Abstract Scope |
Evaluating solidification cracking susceptibility is critical for material qualification in fusion welding and additive manufacturing. Many of existing cracking criteria focus on the material’s composition-based resistance, overlooking the influence of processing conditions. In this study, Houldcroft weldability test is performed where aluminum alloy 7075 sheet is laser welded autogenously. The fishbone-shaped sheet has variable restraints/stiffnesses along the travel direction. To accurately predict the mushy zone temperature field and subsequent stress-strain evolution, a molten pool heat transfer and fluid flow model is integrated with a mechanical model. Numerical predictions are validated by the post-weld metallography, alongside high-speed video and digital image correlation during welding. Existing solidification cracking criteria based on liquid feeding or solid fracture are implemented into the model to evaluate the local crack susceptibility. The accuracy of different cracking criteria is assessed, identifying further enhancements needed to better predict how local stiffness and thermal gradient affect cracking. |