Numerical Modeling of Electron Beam Welding in Precipitation Hardened CuCrZr Alloy

Abstract

Precipitation hardened copper chromium zirconium (PH-CuCrZr) has good mechanical properties, high electrical and thermal conductivity. As a result, thus find its wide application in various industries such as nuclear, aerospace and automotive sectors. One of the specific applications of PH-CuCrZr alloy is in international thermal experimental reactor (ITER) for manufacturing of the first wall and cooling tubes of the diverter. In order to maintain the structural consistency during the welding of PH-CuCrZr alloy components electron beam welding (EBW) process is employed. In the current work, numerical modeling of EBW process during welding of PH-CuCrZr alloy components has been carried out. A three-dimensional finite element (FE) model is developed to predict the output responses (bead penetration and bead width) as a function of EBW input parameters (beam current, acceleration voltage and weld speed). A combined conical and Gaussian heat source is used to model the deep penetration characteristic of the EBW process. Numerical modelling has been carried out by developing user define function (UDF) in Ansys. Present work illustrates that input power and weld speed has a considerable effect on the EBW output responses (bead penetration, bead width). Simulated results are compared with the experimental results and are in good agreement between the finite element model and experimental results.