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Lecture 7 pt
Lecture Topics (
7 p2
Heat Sources for Welding
• Heat sources for welding include:
- exothermic reactions (flames and thermit)
-arcs
- electrical resistance heating
- radiant energy (electron beam, laser)
Lecture 7 p3
Welding Arcs as Heat Sources (
Ire 7 p4
__________________ ~--~~_ ......_II_ _- - -_ _..._
"."..,........................,..."""".
Anode Drop
-10"-5 m
Anode Spot + Potential CV)
Lecture 7 p!
Electron Interactions (
• The energy required to evaporate one electron from a metal
surface is known as the work function
• Conversely when an electron condenses in the surface_it.
releases this energy
Metal Work First
Function ionization
(eV) potential
(V)
Aluminum 4.0 5.96
Barium 2.1 5.19
Calcium 2.2 6.09
Copper 4.3 7.68
Iron 4.5 7.83
Nickel 5 7.61
Potassium 2.2 4.3
Tungsten 4.5 8.1
p6
The Cathode
• Thermionic cathodes operate at high temperatures such that
(e.g. GTAW) electrons are evaporated from the cathode.
• The energy required is derived from incoming positive ions
that are accelerated through the cathode drop region.
• The cathode loses heat through the electron work function,
electron thermal energy, and by conduction through the
electrode and
• The energy balance is:
3kT
Vc =Cathode drop potential
V C I =(<I>e+ )I + qe I =Arc current
2 e <I>e= Cathode work function
k = Bolztmann's constant
T =Temperature (I<)
e =Electron charge
qe = Heat loss to electrode
Lecture 7
Non-Thermionic Cathodes (
p8
... 77 ,-1"9 - r - -s s: - - on
Lecture 7 p!
GTAW Arc Plasma Temperatures (
Cathode
- - - Solid anode
----- Molten anode
mm
I
I
,,,
3 I
,,,
4
,
,,
Anode L._-~--+---+---T----,:--""",~-"""
2 3 4 5 6
Radius (rnml
're7 p10
Arc Column Plasma Jet
• In a static conducting cylinder, the interaction
between the current and its self-induced
magnetic field produces a radial pressure..
J
! ! ! !
p
V~
r
I I I
Lecture 7 P 11
Arc Column Plasma Jet (
7 p12
~_
_~_ _ _ _
# 'W:!t'· ·w :il -
_ _.................- Rlitii;S1
-....- ....- - - - - - - - - - - - - - - - - - - - - - -... z:iil~'i"
0.1
-;lure 7 p13
Arc "Blow" ( ,
P 14
- - - - ~~---- - -
The Anode
• At the anode, electrons are accelerated across the anode
fall potential and condense in the metal surface, thereby
releasing energy
• The anode loses energy by radiation but also gains energy
by radiation and convection from the plasma
• The energy balance at the anode is:
3 kT
(1...m)QA =(ifJA - _ _ + V II +nq
2 e A' P
qa = heat input to ""'rkpiece (anode)
m = fracllonal heat loss by radiation
~ = anode ""'rk Junellon
k = Boltzmann's constant
T = electron temperature
e = electron chaille
VA = anode fall potential
1 = arc current
nqp = heat transfer from arc column
Lecture 7 p
Arc Heat Generation (
• The heat generated by the arc may be divided into three parts:
- the heat generated at the cathode qc = Vc' (-200/0)
- the heat generated in the arc column qP = Vp , (-20%) -
-the heat generated althe anode qa = Va' (-60%)
ure 7 p16
-
GTAW V-I & Heat Transfer
Characteristics
~ 20
~ 18 M
Clllhode
l- ~ Spot Mode
ii 16 ;
• Normal
Ii
IL
u
14 ~ ./'~NTIAl Mode
~ 12
~.,-~~
100
'ANODE HEAT •
.. -
1:;;'-
~
CATHODE
HEAT
L
Lecture 7 p1
Arc Efficiency of Various Processes (
"'...
...-.. .....
~
-
.......
:J
a.
c:
sooo
ni
Q)
J: ....
... S<I to so
Arc Energy kW)
p18
Forces Acting on the Weld Pool
v-
2
1. Gravity
2. Arc Pressure
3. Surface Tension 1
ecture 7 p19
Motion in the weld pool (
magnetohydrodynamic
0.2
forces vary as the square
of current.
.
J.F. Lancaster (Ed) The Physics of Welding, Pergamon, 1986
Ire 7 p20
-------
_ _ilII',..,'_ ...... • •_"._,. _
Lecture 7 p2'
Effects of Weld Pool Motion (
I
I
.1
ra 7 p22