Theory of materials processing/welding

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We focus on improving reliability of heat and fluid flow calculations, tailoring attributes of processed materials, and embedding physico-chemical phenomena in models 

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We numerically model heat and fluid flow during materials processing, particularly welding. We specialize in

    (a) improving reliability of results by optimizing uncertain model parameters,

    (b) tailoring processed material attributes using population based optimization algorithms, and

    (c) embedding physicochemical processes to make models realistic. 

Resulting simulations of geometry, composition and structure of welds/materials solve important problems.

 Click on the images below to view/download animations created using results from our models

Flow and temperature field in friction stir welding

Keyhole mode welding

Weld pool temperature

and velocity fields

Liquid metal flow and

free surface shape

Bead shape development

in GMA welding

Inclusion motion in

the weld pool

Fillet weld development and thermal cycle

Monte Carlo simulation of isothermal grain growth

Grain growth during

welding of Ti-6Al-4V

Cooling during spot welding

Heating and cooling

of spot weld surface

Phase transformation during

 welding of 1005 steel

        User friendly, powerful, welding models for non-specialists

Click on an image below to learn the capabilities of our numerical models of welding.  Review various case studies and experience how the models can help to better understand both the welding process and the welds.

Heat and materials flow in friction stir welding

Heat and fluid flow in Keyhole mode laser welding

Heat and fluid flow in Key-hole mode e-beam welding

Heat and fluid flow in  GTA, laser or e-beam welding

Click on a topic below to view/read a selection of our papers

Reliability of heat and

fluid flow calculations

Tailoring weld attributes using Genetic

Algorithm & Transport Phenomena

Vaporization of alloying

elements during welding

Sulfur, oxygen and

weld geometry

Hydrogen, nitrogen and

oxygen in weld metal

Inclusion characteristics in weld metal

Weld microstructures

Grain structure and

topology (Monte Carlo)

Friction stir welding

Modeling weld defects

Weld surface profiles

Plasma in welding

Neural network

Keyhole mode welding

Spot welding

Electroslag welding

GTA and GMA welding

Fillet welding

Reviews

Slags

Gas stirred ladles

Tundish /AOD process simulation

Composites / solid state

reactions

CVD of diamond, DLC

and silica

Contact email: debroy@psu.edu

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