Validating The Accuracy of Heat Source Model

International Journal of Engineering & Technology IJET-IJENS Vol: 11 No: 05
Validating the Accuracy of Heat Source Model

via Temperature Histories and Temperature
Field in Bead-on-plate Welding
Djarot B. Darmadi
Abstract Welding process generally is modeled as a moving

heat source over a solid. This paper used Goldaks ellipsoidal
moving heat source model. Goldak has proposed a volumetric
heat source model according to the mathematical expressions:
3 x2
'''
( x , y , )
3 y2
3 2
2
2
2
6 3q
r
e rx e y e rz . For a known heat

rx ry rz
input value, crucial parameters of the Goldaks heat source model

are rx, ry and rz. Using rx, ry and rz equal to 5mm, 2mm and 3mm
respectively; a well match temperature histories with
experimental result at observed positions and weld pool shape can
be obtained.
Index Term Goldaks heat source models, temperature
history, temperature field
I. INTRODUCTION
MANY benefits can be achieved through welding simulation.
Production cost can be reduced by limiting try and error of
experimental welding. Using simulation, welding risk can be
minimized in the earliest stage of the product development
cycle. Welding simulation can also ascertain the level and
distribution of residual stresses [1]. Welding simulation can be
used as a tool for study such as material behaviors under
welding phenomenon [2], the effects of weld metal yield
strength to residual stress [3] and the roles of phase
transformation in the residual stress development [4]. Welding
simulation is proposed to be used as assessment tool [5], and it
is expected welding simulation to be used as a complement of
experiment procedure in determining Welding Procedure
Standard (WPS) [6].
Welding process is modeled as a moving heat source over a
solid. Heat source can be modeled as a point heat source [7,8].
Point heat source is heat load with value equal to generated
heat q (J/s) over a nodal at a solid. Heat source may be
modeled as a surface heat source q" (J/m2s) [4,9,10]. Surface
heat source is heat flux that is heat generated over certain area.
The heat flux can be uniformly distributed or distributed
according to Gaussian distribution. Heat source can also be
represented as a volumetric heat source q ' ' ' (J/m3s) [11,12].
Volumetric heat source is a body heat load applies for certain
Djarot B. Darmadi is a Brawijaya University - Indonesia lecturer, he is
studying at University of Wollongong Australia (e-mail :
b_darmadi_djarot@yahoo.co.id or dbd991@uowmail.edu.au )
volume. As in surface heat source, volumetric heat source can

be uniformly distributed or distributed according to certain
pattern.
The welding process involves many different phenomenon
namely thermal, mechanical and metallurgical phenomenons.
In thermal model heat input from heat source is used to heat
and melt the welded metal. The heat is conducted away from
the heat source into base metal and the heat is lost to the
environment by convection and radiation and also by
conduction to contacting bodies. In thermal model temperature
history of certain node and temperature field for certain time
can be observed.
Analysis of welding process is often considered as a coupled
problem. When thermal model is coupled by mechanical
model, the analysis is usually called as Thermo-Mechanical
analysis (TM). Most analysis is performed in two steps:
thermal analysis followed by mechanical analysis. In TM
analysis temperature distribution in thermal analysis is used as
thermal load. Strain and stress as a function of time because of
the thermal load can be observed. Usually the effect of
mechanical model to thermal model is neglected. For certain
material, solid state phase transformation exists when heated to
such high temperature as in welding process. Since phase
transformation affects thermal and mechanical properties of
the welded material, it should be included in the analysis. If
the analysis includes phase transformation considerations, the
analysis is called as Thermo-Mechanical-Metallurgical (TMM)
analysis.
No matter until what extend the analysis will be carried out,
thermal analysis as a basic of welding phenomenon should be
correct. The most important thing in the thermal analysis is the
heat source model. The defects on the heat source model
mislead the next analysis. In this paper the accurate model of
heat source of bead-on-plate welding is proposed. The
validation is done by observing temperature histories of
measured nodes and comparing the predicted and measured
weld-pool shape.
II. GAUSSIAN SURFACE HEAT SOURCE MODEL
Since heat torch transmits heat over a surface, surface heat
source (heat flux) is closer to the real condition than point heat
source. Instead of uniformly distributed, many researchers
have used distributed surface disc heat source model according
111505-6868 IJET-IJENS @ October 2011 IJENS
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to Gauss distribution. For Gaussian distributed heat source,
heat at certain distance (ri) from heat source centre has value
according to equation 1.
qi" q0" e C ri / ro
(1)
where q0" is heat flux generated at the center of heat source

model, ro is the outer disc radius and C is an arbitrarily
constants. It is generally assumed that the heat value at the
outer radius is 5% of the maximum heat at the center of heat
source. Using this assumption, the constant C is closed to 3
and equation (1) can be represented as in equation 2.
qi" q0" e 3ri / ro
(2)
In Cartesian x-y coordinate system, equation (2) can be

expressed as in equation (3).
q q e
"
i
"
0
3 x2
ro2
3 y2
ro2
(3)
III. GOLDAK VOLUMETRIC HEAT SOURCE MODEL

The volumetric moving heat source model is pioneered by
Goldak et.al. [13]. The existence of digging and stirring of arc
welding such as distributed pressure, surface tension and
buoyancy forces have been known in practical welding. Since
all of those phenomenons are distributed throughout a volume
of material, Goldak introduced volumetric heat source. The
relation between welding physics and volumetric heat source
model is well described by Gilles et.al. [14] as shown at figure
1.
10
A, B and C are constants; q0''' is volumetric heat source

generated at heat source center. For simplification, Goldak
assumed weld plate as an infinite solid. Considering energy
conservation and that welding applied on a plate, i.e. semi
infinite solid, equation (5) is obtained.
2q 2VI 8 q0'''e Ax
By 2 C 2
dxdyd
(5)
0 0 0
where is welding efficiency, V is voltage (volt) and I is

electrical current (amp).
It is known mathematically that et 2 dt 1 .erf (t ) , and
at the limits
t 2
dt
1
. As a result equation (5) can be
2
written as in (6).
2q
q0'''
ABC
(6)
Analog to Gaussian distributed surface heat source model,

the ratio between the minimum heat flux at the center of
ellipsoid and maximum heat flux at the ellipsoid center is
taken as 5%. Hence for elements at (rx,0,0), (0,ry,0) and
(0,0,rz) q("x , y , ) 5%q0''' ; and using equation (4) and (6),
equation (7) can be obtained for the Goldak heat source
model.
3 x2
'''
( x , y , )
3 y2
3 2
2
2
2
6 3q
r
e rx e y e rz
rx ry rz
The maximum value of equation (7) is q '''

0
(7)
6 3q
at
rx ry rz
position (0,0,0). Considering this condition and substituting

3x 2 3 y 2 3 2
re2 2 2 2 , equation (7) can be simplified to
rx
ry
rz
equation (8).
q('''x , y , ) q0'''e re
If the welding process moves parallel to the z axis, and

represents a moving abscissa parallel to the z axis, the heat
load at a certain small increment volume inside an ellipsoid
can be expressed by distributed volumetric heat load as
expressed by equation (4).
2
2
2
(4)
q ' ' '( x , y , ) q0'''e Ax By C
(8)
IV. EXPERIMENT PROCEDURE BY NET

A major issue in modeling is accuracy and validity. To this
end the European Network on Neutron Techniques
Standardization for Structural Integrity (NeT) has published
experimental data and procedures which can be accessed at
https://odin.jrc.ec.europa.eu [15,16]. Experimental work was
carried out using bead-on-plate (bop) welding. Nine
thermocouples were attached at different measured points. The
welding procedures are summarized in table 1. Four identical
plate specimens (called as A11, A12, A21 and A22) are
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produced. A sketch diagram for the welding set up and
thermocouple positions are presented in figure 2 and figure 3
respectively. It should be noted that the origin of coordinate
system is at the weld stop end. The positions of the
thermocouples based on the chosen coordinate system are
tabulated in table 2.
Four sets of temperature histories for four specimens were

obtained from nine thermocouples. As the thermocouple Tc8
was not pushed far enough into the hole and there is no clear
reference to where the data was recorded, the Tc8
thermocouple was not considered. For thermocouple Tc9, the
data from specimen A21 were also excluded since they showed
11
a lower temperature and inconsistent with data from other

specimens [17].
The temperature dependent properties of the base metal and
welding filler were obtained from NeT [16]. The material
properties for the base metal and the weld metal are shown at
Table 3. The density and Poissons ratio for both materials are
7966 kg/m3 and 0.294 respectively. In figure 4 are shown
thermal properties for both metals graphically.
V.
FEM MODELING
In this paper, finite element model and simulation have been
carried out using ANSYS Parametric Design Language
(APDL) mode due to its flexibility over the Graphics User
Interface (GUI) mode. To obtain a good model of the heat
source, a very fine mesh should be provided in the area where
the heat source will pass through. Equation (7) can be used to
judge how fine the meshes need to be, which depends on r x, ry
and rz values; the higher these values the coarser the mesh
needs to be. Brick elements of 0.3mm brick mesh have been
used. The adequacy of the mesh size is analyzed after rx, ry and
rz values are determined.
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12
A one-half model was used due to symmetry. The model is

comprised of 43,639 nodes and 71,128 elements of solid 70
elements. Denser meshes close to the weld line are needed due
to high temperature gradient at this position. Very fine meshes
in the weld area are needed to match closely the moving heat
source. Dense meshes are also applied at positions surrounding
a thermocouple to locate thermocouple positions accurately.
The final FEM mesh design is shown in figure 5.
Firstly the welding efficiency should be found. Since there

are no experiment data provided by NeT, welding efficiency
was determined by fitting the peak temperature at Tc9. The
thermocouple was chosen since it is least influenced by factors
such as heat source model, and heat from arc radiation. Only
global heat input affects it significantly. Moreover the
thermocouple indicates the temperature at the quasi steady
state and it is easy to locate accurately in FEM mesh. Normally
the welding efficiency of TIG ranges between 65% and 88%
[18]. Estimation of the welding efficiency was made based on
a simple model to save computer time. The finite element
mesh of the simplified model is shown at figure 6. A stepped
mesh was used to decrease the number of elements. The heat
rate intensity q (J/s) can be calculated from the product of the
heat input and welding speed. The heat rate intensity is applied
as point heat load. Data of the heat input and welding speed
are obtained from NeT. Observing peak temperature at Tc9 of
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the simulation result on simplified model, the welding
efficiency was found to be 76%. Convection coefficient and
emissivity are assumed to be 5 W/m2.K and 0.5 respectively.
Ambient temperature is assumed as 25C based on the
averages of thermocouple measurements. Heat source
parameters (rx, ry, rz) are varied as (3mm, 3mm, 3mm), (5mm,
3mm, 3mm), (5mm, 2mm, 3mm) and (5mm, 2mm, 2mm).
Temperature histories and temperature field are evaluated
again experiment data provided by NeT.
Brick mesh sizes along the heat source trajectory are
0.3mm. The body heat source values depend on the distance
from the centroid of the elements to the center of the heat
source. Since the brick mesh sizes are 0.3mm and applying to
equation (7), comparison between q('''x , y , ) / q0''' for each heat
source model is presented at table 4. The least value is 97.90
for [5,2,2] model which means the maximum body heat will be
represented by 97.90% of its value, and it can be assumed that
the mesh size along the weld path is sufficiently fine.
The welding simulation used element birth-and-death

technique approach. In the element birth and death technique,
the metal bead is growing with the moving heat source. First,
all of weld bead elements are omitted using EKILL
command in ANSYS-APDL and the growth is modeled using
EALIVE command. Born elements are elements of the weld
bead which are already left behind the moving heat source.
When the elements are born, their temperature should be at the
melting embedded filler metal temperature which is
superheated at 2400C [19]. Instead of applying temperature
node load, the body heat load rate ( q ''' ) at elements was
applied. The body heat load value is such that it can produce a
temperature of 2400C at the growing weld bead. The heat
needed to elevated the weld pool from the initial temperature
of 25C to 2400C was evaluated using q = mcT. It should
be noted that the specific heat c, is temperature-dependent as
expressed in Table 3b. The specific heat at a certain
temperature range was taken as the mean value between these
ranges. The heat rate can be obtained using q mcT S
v
expression. Finally, the body heat load which should be
applied at the born weld bead can be obtained using equation
(9).
S
(9)
q ' ' ' cT
v
13
VI. RESULTS AND DISCUSSIONS

Temperature histories for varied heat source model are
compared as shown in figure 7. Figure 7a, 7b and 7c describe
temperature histories for thermocouple at the top surface. In
figure 7a are compared temperature histories at weld start
point, Tc1 for the closer thermocouple and Tc4 for the farther
one. Tc1 peak temperature are 245.127C, 257.742C,
254.748C and 251.251.183C for [3, 3, 3], [5, 3, 3], [5, 2, 3]
and [5, 2, 2] respectively. All of those peak temperatures are
achieved when t = 6.495s except for [3, 3, 3] heat source
model which, is obtained when t = 7.024s. Tc4 peak
temperature are 142.980C, 146.441C, 145.543C and
144.111C when time equal to 11.783s, 11.254s, 11.254s and
11.254s for those [3, 3, 3], [5, 3, 3], [5, 2, 3] and [5, 2, 2]
respectively.
Three important notes can be underlined here, first is that
the model with rx = 3mm showed split results with others in
term of peak temperature and when (time) the peak
temperature is achieved. Variation in the other heat source
model (ry and rz) does not show significant difference.
Regarding the coordinate system shown at figures 2 and 3, rx is
the size of ellipsoidal heat source model in the transversal
direction parallel to the surface of the base metal. Tc1 and Tc4
are the positions at surface those perpendicular to the weld
line. It may be the reason why rx affects the temperature
histories of the thermocouple in the coincide direction.
Evaluating standard deviation for Tc1 and Tc4, those are
5.420 and 1.531 respectively. This means Tc1 is more
susceptible to heat source model than Tc4; it is the second
notes that the closer position is more affected by the heat
source model than the farther one. The last but not the least
note is that using lower rx produces lagging time of the peak
temperature. Since the thermocouple is farther from heat
source model for the lower rx the longer time is needed for the
heat from the heat source model to reach the observed
position. Using rx = 3mm the peak temperature for Tc1 is
achieved at 7.024s whilst for rx = 5mm is at 6.495s that
lagging by 0.529s. Evaluating temperature histories for Tc4,
peak temperature for rx = 3mm is at 11.783 whilst for rx =
5mm is at 11.254s. Again the peak temperature with r x = 3mm
is lagging by 0.529s. The other insight which may also
precious is when evaluation is done for the same heat source
model but for different position (Tc1 and Tc4). Evaluating r x =
3mm peak temperatures are at 7.024s and at 11.783s for Tc1
and Tc4 respectively. Longer time for peak temperature of Tc4
is caused by the farther position than Tc1. The time for peak
temperatures differ by 4.759s. Using rx = 5mm peak
temperature for Tc1 and Tc4 are at 6.495s and 11.254 which
also differ by 4.759s with time lagging for Tc4 due to it farther
position to the heat source center.
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Figure 7b describes temperature histories for position in the

middle of weld bead, Tc2 and Tc5 for closer and farther
position respectively. In figure 7c are shown temperature
histories for thermocouple at the weld end point, for the closer
(Tc3) and farther (Tc6) one. The peak temperatures and the
times when the peak temperatures is produced for varied heat
source model and for different position are summarized at
table 5. The same conclusions with thermocouple on the start
point for middle and end point thermocouples can be derived.
Peak temperatures at the middle position show higher values
than the start point thermocouples for the same heat source
model. That higher temperature as a result of the facts that the
middle position has been preheated by the heat source center
before the heat source center derived middle thermocouples z
coordinates.
The lower peak temperatures (compare to the middle
thermocouple) are exhibited by the thermocouple at the weld
end. Although the end point thermocouple are also preheated,
but the weld torch is extinguished instantaneously when the
weld torch center arrives at the end point. This sudden
extinction causes the lower peak temperature.
Next evaluation is done for thermocouple inside the base
metal (Tc7) and bottom-surface thermocouple (Tc9). Peak
temperature and time for the peak temperature for [3, 3, 3], [5,
3, 3], [5, 2, 3] and [5, 2, 2] heat source models at Tc7 are
256.639C, 254.720C, 252.970C and 252.289C
respectively which all achieved at 30.043s. The standard
deviation for the peak temperatures is 1.947. The low standard
15
deviation means no significant affect is observed because of

the heat source model variation. For the Tc9 the peak
temperatures are 200.593C, 200.577C, 199.298C and
198.351C at 33s. The standard deviation is even lower than
the standard deviation for Tc7 (1.087).
Temperature field at the mid-plate cross section are shown
at figure 8 for varied heat source model. The picture describes
temperature fields when heat source exactly at the middle of
the plate, thus it shows the maximum temperature at the cross
section position. It should be noted that the melting
temperature of the base metal is 1400C which means
isothermal line for 1400C also shows weld pool shape.
Observing figure 8, arrives to conclusion that heat source
model with rx, ry and rz equal to 5mm, 2mm and 3mm
respectively gives better weld pool shape than the others. With
the heat source model, the 1400C isothermal lines have the
width equal to the weld-bead.
The next comparison is made between experimental result
with thermal model of [5,2,3] heat source. In figure 9 is shown
comparison between weld-pool shape from [5,2,3] heat source
model and from experimental results. It can be said that the
FEM model of weld pool shape shown good agreement with
the experimental result. Not only has the width of the weldpool matched the experimental cross section but also the depth
of the weld pool.
In figure 10 temperature history from [5,2,3] heat source
model is compared to the experimental results. Four sets of
experimental temperature histories are obtained from four
specimens (A11, A12, A21 and A22). From these figures it
can be concluded that FEM simulation has shown a good
agreement with experimental results. Apart from showing the
general trend, the transient temperature values generally also
match the experimental data. For the close field
thermocouples, the FEM model predicts a lower temperature
than the measured peak temperature. The lower prediction may
be caused by the radiation of torch arc which was not modeled.
The below bead thermocouple (Tc7) from FEM model shows
a higher value than that measured by the thermocouple. The
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below bead thermocouple was inserted 6.5mm deep in a hole

with diameter of 1.2mm. The possibility that the thermocouple
is not fully located at the tip of the hole is high. Incomplete
insertion could result in a larger distance from the heat source
and a lower measured peak temperature. If the measured point
is only 0.5mm farther from the heat source, simulation using
the ANSYS model showed that the peak temperature will fit
with the measured peak temperature.
VII. CONCLUSION
Varied heat source model has no significant difference for
temperature histories at observed positions, however small
different is shown at thermocouples close to the weld-bead.
Temperature field for close positions and weld pool shape are
significantly affected by heat source model. Observing
temperature histories and weld pool shape, heat source model
with rx, ry and rz equal to 5mm, 2mm and 3mm respectively
gives well match results with experimental data.
VIII. FUTURE WORKS
Practically, mechanical properties of resulted welding joint
are more preferable than thermal results (temperature history
or temperature field). The typical recent topic of interest of the
mechanical properties is residual stress. Discussion on residual
stress using the above validated thermal model will be a
precious work.
[1]
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International Journal of Engineering & Technology IJET-IJENS Vol: 11 No: 05