Theoretical and experimental analysis of thermo-mechanical phenomena during electron beam welding process

The goal of the work is the analysis of electron beam welding process parameter impact on the geometry of fusion zone and on the distribution of residual stresses in the specimen. on beam welding technology is used in the aircraft industry to join structural and load bearing elements made of titanium and aluminum alloys, and landing gears made of high strength steel. series of experiments 49 welds were created for chrome-nickel steel plates using different values of welding control parameters. The analyzed parameters included welding speed, beam current, accelerating voltage, beam focus, beam deflection and frequency. Partial Least Square method was used to build the models predicting the geometry of fusion zone cross-section based on the values of the control parameters. Three models were created predicting fusion zone cross-section depth and width, area and shape. formation about fusion zone geometry was subsequently used to define heat source. The numerical model based on Finite Element Method utilized heat source model to describe the evolution of temperature and stress field during and after welding process. The calculated temperature field was compared against the shape of the actual fusion zone. The PLS-FEM model predicted the shape of fusion zone with satisfying accuracy. The values of calculated residual stresses were compared with X-ray diffraction measurements.